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Lincoln Electric RED-D-ARC E500, Operator'S Manual

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Lincoln Electric RED-D-ARC E500 Operator'S Manual Download Page 28

E-8

TROUBLESHOOTING

POWER WAVE

®

E500

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

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).

• Verify the cables are fully inserted into

the bulk head connector.

2. IP address information.

2. Use Weld Manager (included on the

POWER WAVE

®

Utilities or available at

www.powerwavesoftware.com) to verify
the correct IP address information has
been entered.

NOTE: 

• The Power Wave E500 has a default

static IP address of 192.16.8.0.2.

• Verify no duplicate the IP addresses exist

on the network. 

Connection Drops while welding.

1. Cable Location.

1. Verify Network cable is not located next

to current carrying conductors.  This
would include input power cables and
welding output cables.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your 

Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

Summary of Contents for RED-D-ARC E500

Page 1: ...om register Authorized Service and Distributor Locator www lincolnelectric com locator IM10370 A Issue Date Oct 16 Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 12643 Save for future reference Date Purchased Code ex 10859 Serial ex U1060512345 ...

Page 2: ...N 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 symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked WEAR CORRECT EYE EAR BODY PROTECTION PROTECT your eyes and face with welding helmet properly fitted...

Page 3: ...ers 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 th...

Page 4: ...m 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 suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes an...

Page 5: ...ent 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 NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy MA 022690 9101 6 j Do not use a welding power source for pipe...

Page 6: ...E AND VOLTAGE SENSING CONNECTIONS A 8 TYPICA INTEGRATED SYSTEMS SINGLE ARM A 9 OPERATION Section B POWER UP SEQUENCE B 1 DUTY CYCLE B 2 COMMON WELDING PROCEDURES B 3 ACCESSORIES Section C MAINTENANCE Section D VISUAL INSPECTION D 1 ROUTINE MAINTENANCE D 1 PERIODIC MAINTENANCE D 1 TROUBLESHOOTING Section E HOW TO USE TROUBLESHOOTING GUIDE E 1 USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS E 2...

Page 7: ...ne to operate reliably in harsh industrial environments EqUIPmENT LImITaTIONS The Power Wave E500 is only compatible with the Lincoln Electric wire feeders listed in the compatible equipment section It does not support any semi automatic welding The Power Wave E500 is also compatible only with robotic controllers that support ArcLink XT DESIGN FEaTURES Compact Durable Case Tough IP23 enclosure rat...

Page 8: ...Size Type 75C Copper Wire in Conduit AWG IEC Sizes 40C 104 F Ambient Type 75C Copper Ground Wire in Conduit AWG IEC Sizes Cord Size AWG Sizes IEC 380 3 60 50 31 A 50 10 6 10 6 8 8 400 415 3 60 50 30 A 50 10 6 10 6 8 8 RATED OUTPUT Process Duty Cycle Volts at Rated Amperes Amperes Efficiency at Rated Output GMAW CV FCAW G 60 39 V 500 A 89 100 36 5 V 450 A GMAW P CV 60 39 V 500 A 100 36 5 V 450 A PH...

Page 9: ...electrical power is provided by the public low voltage supply system There can be potential difficulties in residential locations due to conducted as well as radiated radio frequency disturbances The EMC or RF classi fication of this equipment is Class A HIGH FREqUENCY PROTECTION Locate the Power Wave E500 away from radio controlled machinery The normal operation of the machine may adversely affec...

Page 10: ...ion is a steady green light For more information and a detailed listing see the troubleshooting section of this document or the Service Manual for this machine See Troubleshooting Section for operational functions 5 Ethernet Shielded Used for ArcLink XT communication Also used for diagnostics and reprogramming the POWER WAVE E500 6 Wire Feeder Receptacle 14 pin Robotic Wire feeder connector for 4R...

Page 11: ... Connection Terminal Block A ground terminal with the symbol shown is provided separate from this block for connecting the ground lead of the line cord See your local and national electrical codes for proper grounding methods 5 OPTION Base Mounting Kit Input Fuse and Supply Wire Considerations Refer to Page A 1 for recommended fuse wire sizes and type of the copper wires Fuse the input circuit wit...

Page 12: ...e 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 bad connections ROUTE ALL CABLES DIRECTLY TO THE WORK AND WIRE FEEDER AVOID EXCESSIVE LENGTHS AND DO NOT COIL EXCESS CABLE Route the electrode and work cables in close proximity to one another to minimize the l...

Page 13: ... to either a conduit or an enclosure are solid conductor shielded cat 5e cable with a drain The drain should be grounded at the source of trans mission For best results route Ethernet cables away from weld cables wire drive control cables or any other current carrying device that can create a fluctuating magnetic field For additional guidelines refer to ISO IEC 11801 Failure to follow these recom ...

Page 14: ...OWER WAVE E500 Wirefeeder Control Cable K1785 XX Robot Controller Power Wave e500 AutoDrive 4R100 ARC Mate 1XXiC Gas Air ArcLink XT Ethernet Connection Work Cable K2163 XX or K1842 XX Electrode Cable K2163 XX or K1842 XX ...

Page 15: ...LTAGE INPUT VOLTAGE OUTPUT VOLTAGE INPUT CURRENT OUTPUT CURRENT PROTECTIVE GROUND WARNING OR CAUTION EXPLOSION DANGEROUS VOLTAGE SHOCK HAZARD READ INSTRUCTION MANUAL OFF HIGH TEMPERATURE CIRCUIT BREAKER 3 PHASE INVERTER NEGATIVE OUTPUT POSITIVE OUTPUT WIRE FEEDER STATUS MACHINE STATUS INPUT POWER THREE PHASE DIRECT CURRENT ARCLINK XT WIREFEEDER Ur U0 U1 U2 I1 I2 ...

Page 16: ... 500 amps based off of a ten minute cycle 6 minutes on time and 4 minutes off time The maximum output of the machine is 500 amps The Power Wave E500 is also rated for Desert Duty elevated temperature operation in a 55 C ambient The machine is de rated for this application WARNING STATUS LIGHTS LIGHT CONDITION MEANING Steady Green System OK Power source is operational and is communicating normally ...

Page 17: ...d WFS set by the operator Basic Welding Controls WELD MODE Selecting a weld mode determines the output characteristics of the Power Wave power source Weld modes are developed with a specific electrode material electrode size and shielding gas See www powerwavesoftware com for a more complete description or a more complete description of the weld modes programmed into the POWER WAVE E500 at the fac...

Page 18: ...for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known Voltage or Trim can be adjusted Trim adjusts the arc length and ranges from 0 50 to 1 50 with a nominal value of 1 00 Trim values greater than 1 00 increase the arc length while values less than 1 00 decrease the arc length See figure B 3 Most pulse welding programs are synergic As the wire feed sp...

Page 19: ...asters and dual cylinder platform Convenient handles allow for easy cable storage Small footprint fits through 30 inch 762mm door K586 1 Deluxe Adjustable Gas Regulator Hose Kit Accommodates Argon or Argon blend gas cylinders Includes a cylinder pressure gauge dual scale flow gauge and 4 3ft 1 3m gas hose K3129 2 CE Filter Kit 3100211 Harris Argon Flowmeter Regulator and Hose Kit K3019 1 Arc Track...

Page 20: ... condition to ensure that high voltage parts are protected and correct spacing is maintained throughout All external sheet metal screws must be in place to ensure case strength and electrical ground continuity PERIODIC maINTENaNCE Thermal Protection Thermostats protect the machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or operating the m...

Page 21: ...s column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE 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 generall...

Page 22: ...k network Blinking Green Occurs during power up or a system reset and indicates the POWER WAVE E500 is mapping identifying each component in the system Normal for first 1 10 seconds after power is turned on or if the system configuration is changed during operation Fast Blinking Green Under normal conditions indicates Auto mapping has failed Also used by the Diagnostics Utility included on the POW...

Page 23: ...ch has occurred on the fault interrupt circuitry Sometimes caused by primary over current fault or intermittent connections in the thermostat circuit 54 84 Secondary output over current The long term average secondary weld current limit has been exceeded This error will immediately turn off the machine output NOTE The long term average secondary current limit is 450 amps 213 513 Communication Faul...

Page 24: ...ck input fuses Make certain that the Power Switch SW1 on the power source is in the ON position 2 Fuse F1 in reconnect area may have blown 2 Power Down and replace the fuse 3 Circuit breaker CB1 on the control panel may have tripped 3 Power Down and reset CB1 4 Improper input voltage selection multiple input voltage machines only 4 Power down check input voltage reconnect according to diagram on r...

Page 25: ...Thermal LED is ON 1 Improper fan operation 1 Check for proper fan operation Fans should run whenever output power is on Check for material blocking intake or exhaust louvers or for excessive dirt clogging cooling channels in machine 2 Output Rectifier board or Choke thermostat 2 After machine has cooled reduce load duty cycle or both Check for material blocking intake or exhaust louvers and heat s...

Page 26: ... calibration 5 Verify the calibration of the output current and voltage 6 Secondary current limit has been reached 6 Adjust procedure to reduce output demand Wire burns back to tip when the arc is initiated 1 Voltage sense lead problem 1 Check sense lead connections Check the sense lead configuration and arc polarity Make sure Electrode and Work connections are not reversed 2 Wire feed problem 2 C...

Page 27: ...he wire feed speed 2 Remove bends and twists in conduit leading to the feeder 3 Conduit leading up to the wire feeder from the wire reel is too long 3 Use a shorter piece of conduit DEVICENET PLC CONTROLLED SYSTEM Bad Weld Starting 1 Wire Feed problem 1 Verify Feeders drive roll tension is not too low allowing the wire to slip in the rolls Verify wire can be pulled easily through the wire conduit ...

Page 28: ...or available at www powerwavesoftware com to verify the correct IP address information has been entered NOTE The Power Wave E500 has a default static IP address of 192 16 8 0 2 Verify no duplicate the IP addresses exist on the network Connection Drops while welding 1 Cable Location 1 Verify Network cable is not located next to current carrying conductors This would include input power cables and w...

Page 29: ...0 6 201 X11 T2 MAIN TRANSFORMER COIL 1 COIL 2 X14 202 204 203 X12 X13 THERMOSTAT 1 30 10 40 P P OUTPUT RECTIFIER HEATSINK ASSEMBLY THERMOSTAT 2 20 P BOOST RELAY L2 REACTER 221 NEG 221 NEG POS L3 REACTER 52A 51A H1 2400 F B B W W YELLOW THERMAL LED B W 220B 221B 42V 24 X5 X4 52V X6 X3 460V 380V 575V H4 H5 H6 T1 AUXILIARY TRANSFORMER FAN G U G N 22 B 23 115V H3 H2 23 H1 0V 0V THERMOSTAT 3 229 230 LO...

Page 30: ...ence only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number L17181 ...

Page 31: ... 1084 C CASE FRONT ASSEMBLY AR 2 P 1084 D DIVIDER PANEL ASSEMBLY AR 3 P 1084 E BASE CENTER ASSEMBLY AR 4 P 1084 F CASE BACK ASSEMBLY AR 5 P 1084 G WRAPAROUND ASSEMBLY AR Index of Sub Assemblies 12643 Power Wave E500 12643 1 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 32: ...P 1084 A jpg Index of Sub Assemblies 12643 2 Power Wave E500 12643 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 33: ...R HANDLE SUPPORT BRACKET 1 7C 9SS9225 66 SELF TAPPING SCREW 4 8A 9SS28626 5 FEEDHEAD PC BD ASBLY 1 8B 9ST9187 13 10 24HLN 1817 1 NYLON INSERT 4 9SG8964 MAIN CONTROL HARNESS 1 9A 9SS12021 72 BOX RECEPTACLE SOLID SHELL 1 9B 9SS8025 96 SELF TAPPING SCREW 2 9C 9SS17062 11 CABLE CONNECTOR CAP 1 9SCF000010 10 24HN 4 9SE106A 1 LOCKWASHER 2 9SS26124 GROUND REFERENCE 1 9SS28393 3 OUTPUT SNUBBER ASBLY 1 9SS...

Page 34: ...1 13B 9SM19969 4 ETHERNET RECEPTACLE COVER 1 14 9SS28834 2 LINE SWITCH LEAD ASSEMBLY 1 9SS9225 68 THREAD FORMING SCREW CUTTING 2 9SS9262 183 PLAIN WASHER 2 9SS9225 66 SELF TAPPING SCREW 2 16 9SM19969 16 ETHERNET PATCH CABLE ASSEMBLY 1 Case Front Assembly 4 Power Wave E500 12643 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 35: ...P 1084 C jpg Case Front Assembly Power Wave E500 12643 5 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 36: ...5 45 THREAD FORMING SCREW 1 4C 9ST9695 17 LOCKWASHER 1 5 9ST13260 4 DECAL EARTH GROUND CONN 1 6 9ST12380 4 BUSHING 1 7 9ST12380 8 BUSHING 1 8A 9ST13637 6 DIODE BRIDGE35A400VF W1 PH 1 8B 9SS9262 27 PLAIN WASHER 1 8C 9SE106A 1 LOCKWASHER 1 8D 9SCF000010 10 24HN 1 9A 9SS13490 157 CAPACITOR ALEL24000100V 300 10 1 9B 9SS11604 65 SET SCREW 2 9SS18250 955 PLUG LEAD ASBLY 1 9D 9SS9262 23 PLAIN WASHER 2 9E...

Page 37: ...INSULATOR 2 14B 9ST11267 B INSULATOR 2 9ST10728 77 FUSE 4A 1 16 9SS18491 1 MOV ASBLY 1 9SS18250 1074 PLUG LEAD ASBLY 1 9SM26138 AUXILIARY TRANSFORMER THERMOSTAT ASSEM 1 18A 9SS13000 129 AUXILIARY TRANSFORMER 1 9ST13359 15 THERMOSTAT 1 18C 9SS9225 32 THREAD FORMING SCREWS 4 18D 9SS9262 98 PLAIN WASHER 4 9SS9225 68 THREAD FORMING SCREW CUTTING 2 Divider Panel Assembly Power Wave E500 12643 7 Printed...

Page 38: ...P 1084 D jpg Divider Panel Assembly 8 Power Wave E500 12643 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 39: ...BLY 1 5B 9SS30871 LEM SUPPORT 1 5C 9SS8025 77 SELF TAPPING SCREW 1 5D 9SS9225 66 SELF TAPPING SCREW 1 9SL11452 8 PLUG LEAD ASBLY 2 6A 9SG7848 TRANSFORMER ASBLY 1 6B 9SS9225 66 SELF TAPPING SCREW 3 7A 9SM24999 OUTPUT RECTIFIER ASBLY 1 7B 9SS9225 66 SELF TAPPING SCREW 2 9SS23730 3 SPACER 2 9SCF000015 1 4 20X1 00HHCS 2 9SS9262 98 PLAIN WASHER 2 9SE106A 2 LOCKWASHER 2 9 9SS28206 13 BRAIDED LEAD 1 10A ...

Page 40: ...6 18X1 25HHCS 1 13B 9SS9262 30 PLAIN WASHER 2 13C 9SE106A 3 LOCKWASHER 1 13D 9SCF000029 5 16 18HN 1 14A 9SCF000040 5 16 18X 75HHCS 1 14B 9SS9262 30 PLAIN WASHER 1 14C 9SE106A 3 LOCKWASHER 1 15A 9SG8986 SWITCHBOARD ASSEMBLY 1 15B 9SS9225 66 SELF TAPPING SCREW 2 9SS18250 1063 PLUG LEAD ASBLY 1 Base Center Assembly 10 Power Wave E500 12643 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 41: ...P 1084 E jpg Base Center Assembly Power Wave E500 12643 11 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 42: ... WASHER 2 6C 9ST4291 A LOCKWASHER 2 6D 9SCF000042 8 32HN 2 7 9SS22752 46 RATING PLATE 1 8A 9SS15122 15 RELAY 1 8B 9SS8025 98 SELF TAPPING SCREW 2 9A 9SS19999 CORD GRIP CONNECTOR 1 9B 9ST14370 3 CONDUIT LOCKNUT 1 9SS9225 68 THREAD FORMING SCREW CUTTING 2 9SS9262 183 PLAIN WASHER 2 9SS9225 66 SELF TAPPING SCREW 2 11A 9SS29938 RECONNECT PANEL COVER 1 11B 9SS9225 68 THREAD FORMING SCREW CUTTING 4 12 9...

Page 43: ...P 1084 F jpg Case Back Assembly Power Wave E500 12643 13 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 44: ...9262 183 PLAIN WASHER 2 2 9SG7802 RIGHT CASE SIDE 1 3A 9SG7798 ROOF 1 3B 9SS9225 68 THREAD FORMING SCREW CUTTING 3 9SG8035 WIRING DIAGRAM 1 5 9SS30277 2 WARRANTY DECAL 1 6 9SS27368 4 DECAL LE LOGO 2 7 9SS27468 POWERWAVE LOGO 2 8 9SS20601 6 WARNING DECAL 1 9 9SS28039 2 DECAL GREEN INITIATIVE 1 Wraparound Assembly 14 Power Wave E500 12643 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 45: ...P 1084 G jpg Wraparound Assembly Power Wave E500 12643 15 Printed 11 01 2016 at 14 11 44 Produced by Enigma ...

Page 46: ...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 l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 47: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 48: ...stomer 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 or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactu...

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