Lincoln-electric IM10133 POWER WAVE R500 User Manual

Operator’s ManualPOWER WAVE ®R500Register your machine: www.lincolnelectric.com/registerAuthorized Service and Distributor Locator: www.lincolnelect

A-4INSTALLATION POWER WAVE®R500A-4Only a qualified electrician shouldconnect the input leads to thePOWER WAVE®R500. Connectionsshould be made in acc

A-5INSTALLATION POWER WAVE®R500A-5GMAW (MIG) WELDINGAn arclink compatible wire feeder is recommended forMig welding. Refer to Figure A.3 for the co

A-6INSTALLATION POWER WAVE®R500A-6RECOMMENDED WORK CABLESIZES FOR ARC WELDINGConnect the electrode and work cables between theappropriate output stu

A-7INSTALLATION POWER WAVE®R500A-7FIGURE A.5BACWORKPOWERWAVER500CABLE INDUCTANCE AND ITSEFFECTS ON WELDINGExcessive cable inductance will cause the

A-8INSTALLATION POWER WAVE®R500A-8Electrode Voltage SensingThe remote ELECTRODE sense lead (67) is built intothe 5-pin arclink control cable and is

A-9INSTALLATION POWER WAVE®R500A-9VOLTAGE SENSINGCONSIDERATIONS FOR MULTIPLEARC SYSTEMSSpecial care must be taken when more than one arcis welding s

A-10INSTALLATION POWER WAVE®R500A-10• For circumferential applications, connect all workleads on one side of the weld joint, and all of thework volt

A-11INSTALLATION POWER WAVE®R500A-11CONTROL CABLE CONNECTIONSGeneral GuidelinesGenuine Lincoln control cables should be used at alltimes (except whe

B-1OPERATIONPOWER WAVE®R500B-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®R500 is a portable multi-processpower source with high-end functionality capable ofSti

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

3. FEEDER STATUS LED - A two color LED thatindicates system errors. The Power Wave R500 isequipped with two indicators. One is for the invert-er power

B-4OPERATIONB-4POWER WAVE®R500CASE BACK CONTROLS(See Figure B.2)1. 115 VAC CIRCUIT BREAKER2. 115 VAC RECEPTACLES3. WIRE FEEDER RECEPTACLE4. SYNC TANDE

B-5OPERATIONB-5POWER WAVE®R500COMMON 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®R500 will automatically recalculate the wa

C-1ACCESSORIESC-1POWER WAVE®R500KITS, OPTIONS AND ACCESSORIESAll Kits Options and Accessories are found on theWeb site: (www.lincolnelectric.com)FACTO

D-1MAINTENANCED-1POWER WAVE®R500SAFETY PRECAUTIONSWARNINGELECTRIC SHOCK can kill.•Do not operate with coversremoved.• Turn off power source beforeinst

E-1TROUBLESHOOTINGE-1POWER WAVE®R500If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-2TROUBLESHOOTINGE-2POWER WAVE®R500If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con

E-3TROUBLESHOOTINGE-3POWER WAVE®R500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

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

E-4TROUBLESHOOTINGE-4POWER WAVE®R500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-5TROUBLESHOOTINGE-5POWER WAVE®R500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-6TROUBLESHOOTINGE-6POWER WAVE®R500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-7TROUBLESHOOTINGE-7POWER WAVE®R500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

E-8TROUBLESHOOTINGE-8POWER WAVE®R500Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proc

F-1DIAGRAMSF-1POWER WAVE®R500NOTE: 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®R500L16215A.0113.9422.4527.436.0018.3524.76

POWER WAVE®R500P-710P-710PARTS LIST FORPOWER WAVE®R500This parts list is provided as an informative guide only.This information was accurate at the ti

P-710-AP-710-A431208-15-2012POWER WAVE®R500

08-15-2012POWER WAVE®R500Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers

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

MISCELLANEOUS ITEMS (THESE ITEMS ARE NOT ILLUSTRATED)Wiring Harness (Primary) G7141 1 X08-15-2012POWER WAVE®R500Use only the parts marked “x” in the c

POWER WAVE®R500NOTES

08-15-2012POWER WAVE®R500P-710-CP-710-CCase Front Assembly2C2C2D2D2E2E222220202B2B2D2D2E2E3A3A5A5A5B5B242415B15B15A15A14A14A26C26C25C25C31A31A17A17A31

Case Front Assembly (G7162-2), Includes: NSS 1X1 Case Front G7110 1 X2 LED Harness (Not Shown), Includes: M22487-1 1 X2A LED Panel Mount Assembly (Not

08-15-2012POWER WAVE®R500P-710-DP-710-DBase & Power Conversion Assembly223B3B8A8A8B8B8C8C1A1A4A4A10A10A14A14A10E10E10B10B323230A30A31A31A21A21A23A

1 Base Assembly (G7164-2), Includes: NSS 1X1A Base L15254 1 X1B Thread Forming Screw (Not Shown) S9225-99 6 X2 Base Extrusion M21251-2 2 X3A Attachmen

23A Ground Lug S28841 1 X23B 1/4-20 x .625 HHCS (Not Shown) CF000013 1 X23C Lock Washer (Not Shown) T9695-17 1 X30A Power Conversion Assembly G7150 1

POWER WAVE®R500NOTES

08-15-2012POWER WAVE®R500P-710-EP-710-ECase Back Assembly1A1A2A2A4A4A9A9A10A10A15A15A11B11B11A11A10B10B13A13A10C10C8A8A8A8A121216168B8B8B8B5B5B1717323

Case Back Assembly (G7163-2), Includes: NSS 1X1A Fan Bracket G7186 1 X1B #10-24 HLN (Not Shown) T9187-13 4 X2A Fan Assembly M22853 3 X2B Machine Screw

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

08-15-2012POWER WAVE®R500P-710-FP-710-FRoof Assembly2A2A6A6A7B7B7C7C7A7A7D7D7E7E7F7F7G7G3A3A10A10A141412A12A13A13A13B13B13C13C1A1A1B1B1C1C16A16A16B16B

1 Roof Assembly, Includes: L15724-1 1 X1A Roof L12763-6 1 X1B Warranty Decal (G7456-3) (Part of G7456) NSS 1X1C Warning Decal L8064-1 1 X1E Thread For

16C Lock Washer (Not Shown) E106A-27 8 X08-15-2012POWER WAVE®R500Use only the parts marked “x” in the column under theheading number called for in the

NOTES POWER WAVE®R500

NOTES POWER WAVE®R500

NOTES POWER WAVE®R500

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

viviTABLE OF CONTENTSPageInstallation...

A-1INSTALLATION POWER WAVE®R500A-1TECHNICAL SPECIFICATIONS - POWER WAVE®R500 RECOMMENDED INPUT WIRE AND FUSE SIZES 1INPUTVOLTAGE / PHASE/FREQUENCY20

A-2INSTALLATION POWER WAVE®R500A-2PHYSICAL DIMENSIONSTEMPERATURE RANGESHEIGHT22.45 in ( 570 mm)MODELK3169-1WIDTH14.00in ( 356 mm)DEPTH24.80in ( 630m

A-3INSTALLATION POWER WAVE®R500A-3SAFETY PRECAUTIONS Read thisentire installation section before you start installa-tion.ELECTRIC SHOCK can kill.• O