Lincoln-electric IM10118 POWER WAVE S500 User Manual

Operator’s ManualPOWER WAVE ®S500Register your machine: www.lincolnelectric.com/registrationAuthorized Service and Distributor Locator: www.lincolne

A-4INSTALLATION POWER WAVE®S500A-4Only a qualified electrician shouldconnect the input leads to thePOWER WAVE®S500. Connectionsshould be made in acc

A-5INSTALLATION POWER WAVE®S500A-5CONNECTION DIAGRAMSGTAW (TIG) WELDINGA user interface is required for adjusting the TIG weld-ing settings. S-seri

A-6INSTALLATION POWER WAVE®S500A-6SMAW (STICK) WELDINGSimilar to TIG welding a user interface is required foradjusting the Stick welding settings.

A-7INSTALLATION POWER WAVE®S500A-7GMAW (MIG) WELDINGAn arclink compatible wire feeder is recommended forMig welding. Refer to Figure A.4 for the co

A-8INSTALLATION POWER WAVE®S500A-8RECOMMENDED WORK CABLESIZES FOR ARC WELDINGConnect the electrode and work cables between theappropriate output stu

A-9INSTALLATION POWER WAVE®S500A-9FIGURE A.5BACWORKPOWERWAVES500CABLE INDUCTANCE AND ITSEFFECTS ON WELDINGExcessive cable inductance will cause the

A-10INSTALLATION POWER WAVE®S500A-10Electrode Voltage SensingThe remote ELECTRODE sense lead (67) is built intothe 5-pin arclink control cable and i

A-11INSTALLATION POWER WAVE®S500A-11VOLTAGE SENSINGCONSIDERATIONS FOR MULTIPLEARC SYSTEMSSpecial care must be taken when more than one arcis welding

A-12INSTALLATION POWER WAVE®S500A-12• For circumferential applications, connect all workleads on one side of the weld joint, and all of thework volt

A-13INSTALLATION POWER WAVE®S500A-13CONTROL CABLE CONNECTIONSGeneral GuidelinesGenuine Lincoln control cables should be used at alltimes (except whe

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELYWhen this equipment is ship

B-1OPERATIONPOWER WAVE®S500B-1• ELECTRIC SHOCK CAN KILL. • Do not touch electrically livepart or electrode with skin orwet clothing.• Insulate yoursel

B-2OPERATIONB-2PRODUCT DESCRIPTIONPRODUCT SUMMARYThe POWER WAVE®S500 is a portable multi-processpower source with high-end functionality capable ofSti

CASE FRONT CONTROLS(See Figure B.1)1. USER INTERFACE (optional)2. STATUS LED - (See Troubleshooting Section foroperational functions)3. THERMAL LED -

B-4OPERATIONB-4POWER WAVE®S500CASE BACK CONTROLS(See Figure B.2)1. 115 VAC CIRCUIT BREAKER2. 115 VAC RECEPTACLES3. RESERVED FOR FUTURE DEVELOPMENT4. S

B-5OPERATIONB-5POWER WAVE®S500COMMON WELDING PROCEDURESMAKING A WELDThe serviceability of a product or structure utiliz-ing the welding programs is an

B-6OPERATIONB-6SMAW (STICK) WELDINGThe welding current and Arc Force settings can be setthrough a Power Feed™10M or Power Feed™25Mwire feeder. Alterna

B-7OPERATIONB-7Most pulse welding programs are synergic. As thewire feed speed is adjusted, the POWER WAVE®S500 will automatically recalculate the wa

C-1ACCESSORIESC-1POWER WAVE®S500KITS, OPTIONS AND ACCESSORIESAll Kits Options and Accessories are found on theWeb site: (www.lincolnelectric.com)FACTO

STICK OPTIONSACCESSORY KIT - 150 AmpFor stick welding. Includes 20 ft.(6.1m) #6 electrode cable with lug,15 ft. (4.6m) #6 work cable withlugs, headshi

D-1MAINTENANCED-1POWER WAVE®S500SAFETY PRECAUTIONSWARNINGELECTRIC SHOCK can kill.•Do not operate with coversremoved.• Turn off power source beforeinst

SECTION A:WARNINGS CALIFORNIA PROPOSITION 65 WARNINGSDiesel EnginesDiesel engine exhaust and some of its constituents are known to the State of Calif

E-1TROUBLESHOOTINGE-1POWER WAVE®S500If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-2TROUBLESHOOTINGE-2POWER WAVE®S500If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-3TROUBLESHOOTINGE-3POWER WAVE®S500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-4TROUBLESHOOTINGE-4POWER WAVE®S500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-5TROUBLESHOOTINGE-5POWER WAVE®S500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-6TROUBLESHOOTINGE-6POWER WAVE®S500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-7TROUBLESHOOTINGE-7POWER WAVE®S500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-8TROUBLESHOOTINGE-8POWER WAVE®S500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

F-1DIAGRAMSF-1POWER WAVE®S500NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific

F-2DIMENSION PRINTF-2POWER WAVE®S500L16215A.0113.9422.4527.436.0018.3524.76

ELECTRIC SHOCK CAN KILL.3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts wi

NOTES POWER WAVE®S500

POWER WAVE®S500P-690P-690PARTS LIST FORPOWER WAVE®S500This parts list is provided as an informative guide only.It was accurate at the time of printing

P-690-AP-690-A431209-23-2013POWER WAVE®S500

10-13POWER WAVE®S500Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers not

MISCELLANEOUS ITEMS (THESE ITEMS ARE NOT ILLUSTRATED)Wiring Harness (Primary) G7141 1 XEthernet Cable M19969-2 1 X09-23-2013POWER WAVE®S500Use only th

POWER WAVE®S500NOTES

09-23-2013POWER WAVE®S500P-690-CP-690-CCase Front Assembly2C2C2D2D2E2E222220202B2B2D2D2E2E3A3A5A5A5B5B242415B15B15A15A14A14A26C26C25C25C31A31A17A17A31

Case Front Assembly (G7162), Includes: NSS 1X1 Case Front G7110 1 X2 LED Harness (Not Shown), Includes: M22487-1 1 X2A LED Panel Mount Assembly (Not S

09-23-2013POWER WAVE®S500P-690-DP-690-DBase & Power Conversion Assembly223B3B8A8A8B8B8C8C1A1A4A4A10A10A14A14A10E10E10B10B323230A30A31A31A21A21A23A

1 Base Assembly (G7164), Includes: NSS 1X•1 Base Assembly (G7164-4), Includes: NSS 1 • X1A Base L15254 1 X X1B Thread Forming Screw (Not Shown) S9225-

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the

23A Ground Lug S28841 1 X X23B 1/4-20 x .625 HHCS (Not Shown) CF000013 1 X X23C Lock Washer (Not Shown) T9695-17 1 X X30A Power Conversion Assembly G7

POWER WAVE®S500NOTES

09-23-2013POWER WAVE®S500P-690-EP-690-ECase Back Assembly1A1A2A2A4A4A9A9A10A10A14A14A15A15A11B11B11A11A10B10B13A13A10C10C8A8A8A8A121216168B8B8B8B5B5B1

Case Back Assembly (G7163), Includes: NSS 1X•Case Back Assembly (G716-3), Includes: NSS 1•X1A Fan Bracket G7186 1 X X1B #10-24 HLN (Not Shown) T9187-1

25A Cover Plate S28547 1 X X25B Thread Forming Screw (Not Shown) S9225-99 2 X X25C Plug Button T10397-4 1 X X28 Thread Forming Screw (Not Shown) S9225

POWER WAVE®S500NOTES

Oct-13POWER WAVE®S500P-690-FP-690-FRoof Assembly5A5A2B2B18182A2A5B5B5C5C15A15A7B7B8A8A8B8B8C8C8E8E8D8D7C7C7A7A7D7D7E7E7F7F7G7G9C9C1A1A3A3A1B1B1C1C6A6A

1 Roof Assembly, Includes: L15724-1 1 X X1A Roof L12763-6 1 X X1B Warranty Decal (G7172-3) (Part of G7172) NSS 1XX1C Warning Decal L8064-1 1 X X1E Thr

POWER WAVE®S500NOTES

NOTES POWER WAVE®S500

viviTABLE OF CONTENTSPageInstallation...

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cu

A-1INSTALLATION POWER WAVE®S500A-1TECHNICAL SPECIFICATIONS - POWER WAVE®S500 RECOMMENDED INPUT WIRE AND FUSE SIZES 1INPUTVOLTAGE / PHASE/FREQUENCY20

A-2INSTALLATION POWER WAVE®S500A-2PHYSICAL DIMENSIONSTEMPERATURE RANGESHEIGHT22.45 in ( 570 mm)MODELK2904-1WIDTH14.00in ( 356 mm)DEPTH24.80in ( 630m

A-3INSTALLATION POWER WAVE®S500A-3SAFETY PRECAUTIONS Read thisentire installation section before you start installa-tion.ELECTRIC SHOCK can kill.• O