Lincoln Electric HOT ROD 500S User manual

IM3041
09/2023
REV04
HOT ROD 500S
OPERATOR’S MANUAL
ENGLISH
Lincoln Electric Bester Sp. z o.o.
ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland
www.lincolnelectric.eu

English I English
12/05
THANK YOU! For choosing the QUALITY of the Lincoln Electric products.
Please check packaging and equipment for damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For ease of use, please enter your product identification data in the table below. Model Name, Code & Serial Number
can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications...................................................................................................................................................... 1
Electromagnetic Compatibility (EMC).................................................................................................................................. 2
Safety.................................................................................................................................................................................. 3
Installation and Operator Instructions.................................................................................................................................. 5
WEEE ................................................................................................................................................................................. 9
Spare Parts ......................................................................................................................................................................... 9
Authorized Service Shops Location .................................................................................................................................... 9
Electrical Schematic............................................................................................................................................................ 9
Accessories....................................................................................................................................................................... 10

English 1 English
Technical Specifications
NAME INDEX
HOT ROD 500S K14089-2
INPUT
Input Voltage U1EMC Group / Class Frequency
HOT ROD 220/380/440V / 3~ II / A 50 / 60 Hz
500S
Input Power at Rated Cycle Input Amperes I1max cos φ
HOT ROD
43 kVA @ 35 Duty Cycle (40°C)
220V 3~ 114A
0,89
500S 380V 3~ 65,5A
440V 3~ 57A
RATED OUTPUT
Duty Cycle 40°C / 55°C
(
based on a 10 min. period
)
Output Current Output Voltage
HOT ROD 35% / 25% 600A 44 V
500S 60% / 35% 500A 40 V
100% / 60% 375A 35 V
OUTPUT RANGE
Welding Current Range Peak Open Circuit Voltage
HOT ROD 50A - 625A 65,5 V
500S
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or Circuit Breaker Size Power Lead
220V~ 380V~ 440V~
HOT ROD D 125 A D 63 A D 63 A 4 Conductor, 16mm2
500S
DIMENSION
Weight Height Width Length
HOT ROD 203 kg 795 mm 566 mm 813 mm
500S
OTHERS
Protection Rating Operating Humidity (t=20°C) Operating Temperature Storage Temperature
IP23 ≤90 % from -10 ºC to +55 ºC from -25 ºC to +55 ºC

English 2 English
Electromagnetic Compatibility (EMC)
11/04
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this
section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
This machine has been designed to operate in an industrial area. To operate in a domestic area it is necessary
to observe particular precautions to eliminate possible electromagnetic disturbances. The operator must install
and operate this equipment as described in this manual. If any electromagnetic disturbances are detected the
operator must put in place corrective actions to eliminate these disturbances with, if necessary, assistance from
Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the machine.
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure that
all equipment in the area is compatible. This may require additional protection measures.
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
taking place.
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
additional precautions such as filtering the input supply.
The output cables should be kept as short as possible and should be positioned together. If possible connect the work
piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the work
piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
applications.
WARNING
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radio-frequency disturbances.
WARNING
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to:
HOT ROD 500S: Ssc ≥12 MVA
at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the
equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected
only to a supply with a short circuit power Ssc greater than or equal to data on the table above.

English 3 English
Safety
01/11
WARNING
This equipment have to be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or equipment damage. Read
and understand the following explanations of the warning symbols. Lincoln Electric is not responsible for damages caused
by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury, loss
of life, or equipment damage. Protect yourself and others from possible serious injury or death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this
equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause
serious personal injury, loss of life, or equipment damage.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the electrode,
work clamp, or connected work pieces when this equipment is turned on. Insulate yourself from the
electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off the input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder
directly on the welding table or any other surface in contact with the work clamp to avoid the risk of
accidental arc ignition.
ELECTROMAGNETIC FIELD MAY BE DANGEROUS: Electric current flowing through any conductor
creates electromagnetic field (EMF). EMF fields may interfere with some pacemakers, and welders having
a pacemaker shall consult their physician before operating this equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and
EN 12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal
Protective Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by
EN169 Standard.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough
ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing. To protect the skin, use suitable clothing made
of durable, fireproof material. Protect other nearby personnel with suitable, non-flammable screening and
warn them not to watch the arc nor expose themselves to the arc.

English 4 English
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area
and have a fire extinguisher easily accessible. Welding sparks and hot materials from the welding process
can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks, drums,
containers, or material until the proper steps have been taken to insure that no flammable or toxic vapors
will be present. Never use this equipment when flammable gases, vapors or flammable liquids are
present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving materials
in the work area.
CYLINDER MAY EXPLODE IF DAMAGED: Use only certificate, compressed gas cylinders containing the
correct shielding gas for the process used and properly operating regulators designed for the gas and
pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do not
move or transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode
holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located
away from areas where they may be subjected to physical damage or the welding process including
sparks and heat sources.
MOVING PARTS ARE DANGEROUS: There are moving mechanical parts in this machine, which can
cause serious injury. Keep your hands, body and clothing away from those parts during machine starting,
operating and servicing.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an
environment with increased risk of electric shock.
The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time the
operator’s manual.

English 5 English
Installation and Operator Instructions
Read this entire section before installation or operation of
the machine.
WARNING
Do not lift this machine using lift bail if it is equipped with a
heavy accessory such as trailer or gas cylinder.
Lift only with equipment of adequate lifting capacity.
Be sure machine is stable when lifting.
The HOT ROD 500S welders can be stacked three high
when the following precautions are observed:
Be sure the bottom machine is on a firm, level surface
suitable for the total weight (610kg) of the stacked
machines.
Stack the machine with the fronts flush.
Be certain the pins on the top font corners of the lower
machines fit through the holes in the base rails of the
upper machines.
This machine will operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation:
Do not place or operate this machine on a surface with
an incline greater than 15° from horizontal.
Do not use this machine for pipe thawing.
This machine must be located where there is free
circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover the
machine with paper, cloth or rags when switched on.
Dirt and dust that can be drawn into the machine
should be kept to a minimum.
This machine has a protection rating of IP23. Keep it
dry when possible and do not place it on wet ground
or in puddles.
Locate the machine away from radio controlled
machinery. Normal operation may adversely affect the
operation of nearby radio controlled machinery, which
may result in injury or equipment damage. Read the
section on electromagnetic compatibility in this
manual.
Do not operate in areas with an ambient temperature
greater than 55°C.
The duty cycle of a welding machine is the percentage of
time in a 10 minute cycle at which the welder can operate
the machine at rated welding current.
Example: 60% duty cycle:
Welding for 6 minutes Break for 4 minutes
Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.
The machine is protected from overheating by a
temperature sensor.
When the machine is overheated the output of the
machine will turn "OFF", and the Thermal Indicator Light
will turn "ON". When the machine has cooled to a safe
temperature the Thermal Indicator Light will go out and
the machine may resume normal operation.
Minutes
or decrease
duty cycle
WARNING
Only a qualified electrician can connect the welding
machine to the supply network. Installation the outlet plug
to power lead and connecting the welding machine had to
be made in accordance with the appropriate National
Electrical Code and local regulations.
Check the input voltage, phase, and frequency supplied to
this machine before turning it on. Verify the connection of
grounding wires from the machine to the input source.
The allowable input voltages are 3x220V 50/60Hz,
3x380V 50/60Hz and 3x440V 50/60Hz (3x440V: factory
default). For more information about input supply refer to
the technical specification section of this manual and to
the rating plate of the machine.
If it is necessary to change the input voltage:
The input cable must be disconnected from the mains
supply and the machine switched OFF.
Remove the rear shield from the machine.
Reconnect X4, X5 or X8 according to the diagram
below:
3x220V~ 3x440V~3x380V~
220V~
440V~
220V~
X4 X5 X8 X4 X5 X8X4 X5 X8
380V~ 380V~
440V~
220V~
380V~
440V~
Figure 1
Replace the rear shield.
Make sure that the amount of mains power available from
the input supply is adequate for normal operation of the
machine. The necessary delayed fuse (or circuit breaker
with "D" characteristic) and cable sizes are indicated in
the technical specification section of this manual.
Refer to points [1], [13] and [14] of the images below.
WARNING
When powering welder from a generator be sure to turn
off welder first, before generator is shut down, In order to
prevent damage to welder!
Location and Environment
Dut
y
c
y
cle and Overheatin
g
Input Suppl
y
Connection

English 6 English
Refer to points [10], [11] and [12] of the images below.
The recommended output cable size can be found in the
Table below:
Cable length Up to 10 m 10 – 50 m 50 – 75 m
Cable size 70 mm295 mm2 120 mm2
1
2
3
7
4
5
10
6
9
8
11 12
Figure 2
1. Power Switch ON/OFF (I/O): Controls the input
power to the machine. Be sure the power source is
connected to the mains supply before turning power
on ("I").
2. Thermal Overload Indicator: This lamp will
light up when the machine is overheated
and the output has been turned off. This can
occur if the ambient temperature is above
55°C or the duty cycle of the machine has
been exceeded. Leave the machine on to allow the
internal components to cool, when the lamp turns off
normal operation is possible.
3. Power Indicator Light: After input power is
connected and the power switch is turned
on, this lamp will light up to indicate the
machine is ready to weld.
4. HOT START Control: Value in percentage of
nominal value welding current during arc
start current. The control is used to set the
level of the increased current and arc start current is
made easy.
5. ARC FORCE Control: The output current is
temporarily increased to clear short circuit
connections between the electrode and the
workpiece.
6. Output Current Control Range Switch: It allows
selection of the desired welding current range:
LOW range (50A - 320A)
HIGH range (50A - 625A).
7. Digital Welding Current and Voltage Meter with
memory feature (available as an option: see
"Accessories" chapter): Shows the present value of
the welding current and voltage during welding; after
welding it continues to display the average welding
current and voltage for 5 seconds.
8. Welding Current Knob Control:
Potentiometer used to set the output current
on the range 50A - 625A (also during
welding).
9. Local/Remote Switch: Remote Control Unit K10095-
1-15M and K870 can be used with this machine. It
changes control of the Output Current from the
machine Welding Current [8] to the K10095-1-15M or
K870 and vice versa.
10. Remote Control Connector: If a remote
control is used, it will be connected to the
remote connector (see "Accessories"
chapter).
11. Negative Output Terminal: Negative output
connector for the welding circuit (M12 bolt).
12. Positive Output Terminal: Positive output
connector for the welding circuit (M12 bolt).
13
14
Figure 3
13. Rear Shield: Remove to install the reconnect panel
for the proper input voltage (3x220V or 3x380V or
3x440V).
14. Power lead (5m): Connect the supply plug to the
existing input cable that is rated for the machine as
indicated in this manual, and conforms to all
applicable standards. This connection shall be
performed only by a qualified person.
Output Connections
Controls and Operational Features

English 7 English
HOT ROD 500S does not include the electrode holder
with lead necessary and the work lead for SMAW welding,
but the one can be purchased separately (see
"Accessories" chapter).
For starting welding process with SMAW process you
should:
First turn the machine off.
Determine the electrode polarity for the electrode to be
used. Consult the electrode data for this information.
Depending on the polarity of using electrode, connect
the work lead and the electrode holder with lead to
output socket [11] or [12] and lock them. See the
Table 1.
Table 1.
Output socket
POLARITY
DC (+)
The electrode holder
with lead to SMAW [12]
Work lead [11]
DC (-)
The electrode holder
with lead to SMAW [11]
Work lead [12]
Connect the work cable to the welding piece with the
work clamp.
Install the proper electrode in the electrode holder.
Connect the main plug to the outlet mains socket.
Turn the welding machine on.
Set the Local/Remote Switch in required position: local
or remote.
Set the required welding current by welding current
knob control [8].
The welding machine is now ready to weld.
By applying the principle of occupational health and
safety at welding, welding can be begun.
The HOT ROD 500S name plates feature international
symbols in describing the function of the various
components. Below are the symbols used and an
explanation of what each represents.
POWER ON-OFF SWITCH
IOn
Off
Input
CONTROL DIALS
Arc Force
Hot Start
Output Current
OUTPUT CURRENT CONTROL RANGE SWITCH
LOW Output Current Control Dial Range Low
HIGH Output Current Control Dial Range High
OUTPUT CURRENT CONTROL "MACHINE-REMOTE"
SWITCH
Remote Output Current Control
Machine Output Current Control
RATING PLATE
Three Phase Power
Transformer
Rectifier
Rectifier DC Output
Constant Current Characteristic
Shielded Metal Arc Welding
Line Connection
HIGH TEMPERATURE WARNING LIGHT
High Temperature Limit
WARNING
Warning Identification
GROUND
Signifying the Earth (Ground) Connection
Weldin
g
SMAW
(
MMA
)
Process
International S
y
mbolo
gy
Reference

English 8 English
WARNING
For any repair operations, modifications or maintenances,
it is recommended to contact the nearest Technical
Service Center or Lincoln Electric. Repairs and
modifications performed by unauthorized service or
personnel will cause, that the manufacturer’s warranty will
become null and void.
Any noticeable damage should be reported immediately
and repaired.
Routine maintenance (everyday)
Check condition of insulation and connections of the
work leads and insulation of power lead. If any
insulation damage exists replace the lead
immediately.
Check the welding gun condition: replace it, if
necessary.
Check condition and operation of the cooling fan.
Keep clean its airflow slots.
Periodic maintenance (every 200 working hours but at
list once every year)
Perform the routine maintenance and, in addition:
Keep the machine clean. Using a dry (and low
pressure) airflow, remove the dust from the external
case and from the cabinet inside.
If it is required, clean and tighten all weld terminals.
The frequency of the maintenance operations may vary in
accordance with the working environment where the
machine is placed.
WARNING
Do not touch electrically live parts.
WARNING
Before the case of machine will be removed, the machine
had to be turned off and the power lead had to be
disconnected from mains socket.
WARNING
Mains supply network must be disconnected from the
machine before each maintenance and service. After
each repair, perform proper tests to ensure safety.
The business of The Lincoln Electric Company is
manufacturing and selling high quality welding equipment,
consumables, and cutting equipment. Our challenge is to
meet the needs of our customers and to exceed their
expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our
products. We respond to our customers based on the best
information in our possession at that time. Lincoln Electric
is not in a position to warrant or guarantee such advice,
and assumes no liability, with respect to such information
or advice. We expressly disclaim any warranty of any
kind, including any warranty of fitness for any customer’s
particular purpose, with respect to such 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 provision of information or
advice create, expand or alter any warranty with respect
to the sale of our products
Lincoln Electric is a responsive manufacturer, but the
selection and use of specific products sold by Lincoln
Electric is solely within the control of, and remains the sole
responsibility of the customer. Many variables beyond the
control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service
requirements.
Subject to Change – This information is accurate to the
best of our knowledge at the time of printing. Please refer
to www.lincolnelectric.com for any updated information.
Maintenance Centromer Assistance Polic
y

English 9 English
WEEE
07/06
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
12/05
Part List reading instructions
Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service Department
for any code number not listed.
Use the illustration of assembly page and the table below to determine where the part is located for your particular
code machine.
Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate a
change in this printing).
First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machine that
contains a picture-descriptive part number cross-reference.
Authorized Service Shops Location
09/16
The purchaser must contact a Lincoln Authorized Service Facility (LASF) about any defect claimed under Lincoln's
warranty period.
Contact your local Lincoln Sales Representative for assistance in locating a LASF or go to
www.lincolnelectric.com/en-gb/Support/Locator.
Electrical Schematic
Refer to the "Spare Part" manual supplied with the machine.

English 10 English
Accessories
K10376 Adapter M14/DINSe (F) (to connect the welding cables).
*E/H-400A-70-5M The electrode holder with lead - 5m.
*GRD-600A-95-5M Work Lead with the Work Clamp - 5m.
FL060583010 FLAIR 600 Gouging torch with mounted monocable - 2,5m.
* N/B-600A-95-5M 5m-extension cable for gouging torch.
K14090-1 AV Meter Kit
K10095-1-15M Hand Amptrol.
K870 Foot Amptrol.
K10398 15m-extension cable for remote ctrl box.
* Co-operates with K10376