Lincoln Electric POWER WAVE S500 User manual

Operator’s Manual
POWER WAVE ®S500
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IM10118-A | Issue D ate Oct-14
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THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN 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 and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018

SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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 - 5/16/2018

ELECTRIC SHOCK
CAN KILL.
3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage
between the
two can be the total of the open circuit voltage of both
welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS CAN BURN.
4.a. 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 open arc welding. Headshield and filter lens should
conform 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 and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current 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 thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018

Page
Installation.......................................................................................................................Section A
Technical Specifications ...............................................................................................A-1, A-2
Safety Precautions ...............................................................................................................A-3
Location, Lifting .............................................................................................................A-3
Stacking ........................................................................................................................A-3
Tilting.............................................................................................................................A-3
Input and round Connections .....................................................................................A-3
Machine rounding.......................................................................................................A-3
High Frequency Protection............................................................................................A-3
Input Connection ..................................................................................................................A-4
Input Fuse and Supply Wire..........................................................................................A-4
Input Voltage Selection .................................................................................................A-4
Connection Diagram ......................................................................................A-5, A-6, A-7
Recommended Work Cable Sizes ................................................................................A-8
Cable Inductance and its Effects on Welding................................................................A-9
Remote Sense Lead Specifications.....................................................................A-9, A-10
Voltage Sensing Considerations for Multiple Arc Systems................................A-11, A-12
Control Cable Connections ................................................................................................A-13
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
Power-Up Sequence .....................................................................................................B-1
Duty Cycle.....................................................................................................................B-1
raphic Symbols...........................................................................................................B-1
Product Description ..............................................................................................................B-2
Recommended Processes and Equipment ..........................................................................B-2
Equipment Limitations ..........................................................................................................B-2
Design Features ...................................................................................................................B-3
Case Front Controls .............................................................................................................B-3
Case Back Controls..............................................................................................................B-4
Common Welding Procedures................................................................................B-5 thru B-7
________________________________________________________________________________
Accessories .....................................................................................................Section C
Kits, Options / Accessories....................................................................................C-1
Field Installed Options...........................................................................................C-1
Stick Operations ....................................................................................................C-2
________________________________________________________________________
Maintenance........................................................................................................Section D
Safety Precautions ...............................................................................................................D-1
Routine Maintenance ...........................................................................................................D-1
Periodic Maintenance...........................................................................................................D-1
Calibration Specification.......................................................................................................D-1
________________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions ................................................................................................E-1
How to Use Troubleshooting uide.......................................................................E-1
Using Status LED, Error Fault Codes and Input Control Board....................................E-2, E-4
Troubleshooting uide ............................................................................E-5 thru E-8
________________________________________________________________________________
Wiring Diagram and Dimension Print ............................................................Section F
________________________________________________________________________
Parts Pages ...............................................................................................................P-690 Series
_______________________________________________________________________________
6
TABLE OF CONTENTS

TEC NICAL SPECIFICATIONS - POWER WAVE®S500
RECOMMENDED INPUT WIRE AND FUSE SIZES 1
INPUT
VOLTAGE / P ASE/
FREQUENCY
200-208/3/50/60
230/3/50/60
380-415/3/50/60
460/3/50/60
575/3/50/60
TIME DELAY FUSE
OR BREAKER 2
AMPERAGE
100
90
60
45
35
CORD SIZE 3
AWG SIZES
(mm2)
4 (25)
4 (25)
8 (10)
8 (10)
10 (6)
MAXIMUM INPUT
AMPERE RATING AND
DUTY CYCLE
80A, 40%
73A, 40%
41A, 40%
37A, 40%
29A, 40%
RATED OUTPUT
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model
K2904-1
Duty Cycle
40% rating
100% rating
450 Amps
36.5 Volts
550 Amps
41.5 Volts
500 Amps
39 Volts
INPUT
VOLTAGE/P ASE/
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 Output
.95
Input Voltage ± 10%
208/230/400*460/575
50/60 Hz
(includes 380V to 413V)
1. Based on U.S. National electrical Code
2. Also called " inverse time" or "thermal / magnetic" circuit breakers; circuit breakers that have a delay in trip-
ping action that decreases as the magnitude of the current increases
3. Type SO cord or similar in 30°C ambient
A-1
INSTALLATION
POWER WAVE®S500
GMAW
40% 60% 100%
SMAW GTAW-DC
450 Amps
38 Volts
550 Amps
42 Volts
500 Amps
40 Volts
40% 60% 100%
450 Amps
28 Volts
550 Amps
32 Volts
500 Amps
30 Volts
40% 60% 100%

P YSICAL DIMENSIONS
TEMPERATURE RANGES
EIG T
22.45 in ( 570 mm)
MODEL
K2904-1
WIDT
14.00in ( 356 mm)
DEPT
24.80in ( 630mm)
WEIG T
150 lbs (68 kg)*
OPERATING TEMPERATURE RANGE
Environmentally Hardened: -4°F to 104°F (-20C to 40C)
STORAGE TEMPERATURE RANGE
Environmentally Hardened: -40°F to 185°F (-40C to 85C)
PROCESS
MAW
MAW-Pulse
FCAW
TAW-DC
SMAW
OUTPUT RANGE (AMPERES)
40-550A
5-550A
15-550A
OCV (Uo)
Mean Peak
60V
100V
24V
60V
WELDING PROCESS
A-2
INSTALLATION
POWER WAVE®S500
IP23 155º(F) Insulation Class
*Weight does not include input cord.
Thermal tests have been performed at ambient tem-
perature. The duty cycle (duty factor) at 40°C has
been determined by simulation.

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entire installation section before you start installa-
tion.
ELECTRIC S OCK can kill.
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

   POWER WAVE®S500
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
The POWER WAVES500 will operate in harsh envi-
ronments. Even so, it is important that simple preven-
tative measures are followed in order to assure long
life and reliable operation.
• The machine must be located where there is free
circulation of clean air such that air movement in
the back, out the sides and bottom will not be
restricted.
• Dirt and dust that can be drawn into the machine
should be kept to a minimum. The use of air filters
on the air intake is not recommended because nor-
mal air flow may be restricted. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.
• Do not mount the POWER WAVES500 over com-
bustible surfaces. Where there is a combustible
surface directly under stationary or fixed electrical
equipment, that surface shall be covered with a
steel plate at least .060” (1.6mm) thick, which shall
extend not less than 5.90” (150mm) beyond the
equipment on all sides.
A-3
INSTALLATION
POWER WAVE®S500


Both handles should be used when lifting POWER
WAVES500. When using a crane or overhead device
a lifting strap should be connected to both handles.
Do not attempt to lift the POWER WAVES500 with
accessories attached to it.

The POWER WAVES500 cannot be stacked.

Place the machine directly on a secure, level surface
or on a recommended undercarriage. The machine
may topple over if this procedure is not followed.

Only a qualified electrician should connect the
POWER WAVES500. Installation should be made in
accordance with the appropriate National Electrical
Code, all local codes and the information in this man-
ual.

The frame of the welder must be grounded. A ground
terminal marked with a ground symbol is located next
to the input power connection block.
See your local and national electrical codes for prop-
er grounding methods.

Locate the POWER WAVES500 away from radio
controlled machinery. The normal operation of the
POWER WAVES500 may adversely affect the oper-
ation of RF controlled equipment, which may result in
bodily injury or damage to the equipment.
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when
lifting.
• Do not operate machine while
suspended when lifting.
FALLING
EQUIPMENT can
cause injury.
-------------------------------------------------------------


    
     
  




------------------------------------------------------------------------
INPUT CONNECTION
(See Figure A.1)
Use a three-phrase supply line. A 1.40 inch diameter
access hole with strain relief is located on the case
back. Route input power cable through this hole and
connect L1, L2, L3 and ground per connection dia-
grams and National Electric Code. To access the
input power connection block, remove three screws
holding the access door to the side of the machine.
ALWAYS CONNECT THE POWER WAVE GROUND-
ING LUG (LOCATED AS SHOWN IN FI URE A.1)
TO A PROPER SAFETY (EARTH) ROUND.
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Refer to Specification Section for recommended fuse,
wire sizes and type of the copper wires. Fuse the
input circuit with the recommended super lag fuse or
delay type breakers (also called "inverse time" or
"thermal/magnetic" circuit breakers). Choose input
and grounding wire size according to local or national
electrical codes. Using input wire sizes, fuses or cir-
cuit breakers smaller than recommended may result in
"nuisance" shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
INPUT VOLTAGE SELECTION
The POWER WAVE®S500 automatically adjusts to
work with different input voltages. No reconnect switch
settings are required.
The POWER WAVE®S500 ON/OFF
switch is not intended as a service
disconnect for this equipment. Only
a qualified electrician should con-
nect the input leads to the POWER
WAVE®S500. Connections should
be made in accordance with all local and national
electrical codes and the connection diagram locat-
ed on the inside of the reconnect access door of
the machine. Failure to do so may result in bodily
injury or death.
------------------------------------------------------------------------
A-4
INSTALLATION
POWER WAVE®S500
WARNING
WARNING
POWER CONNECTION BLOCK
INPUT CORD STRAIN RELIEF
CONNECTEACH PHASE OF A THREE-PHASE
CONDUCTOR HERE
GROUND CONNECTION
CONNECT GROUND LEAD PER LOCAL
AND NATIONAL ELECTRIC CODE
ROUTEINPUT CORD
THROUGH RELIEF AND
TWIST NUT TO TIGHTEN
INPUT POWER
ACCESS DOOR
FIGURE A.1

CONNECTION DIAGRAMS
GTAW (TIG) WELDING
A user interface is required for adjusting the TI weld-
ing settings. S-series user interface (K3001-2) can be
installed into the power source (Figure A.2). Refer to
the connection diagrams based on the user interface
that is being used. Alternate configurations are possi-
ble depending on the wire feeder that is being used.
Refer to the wire feeder’s manual for alternative config-
urations.
A-5
INSTALLATION
POWER WAVE®S500
RREEGGUULLAATTOORR
FFLLOOWWMMEETTEERR
GGAASSHHOOSSEE
FFOOOOTTAAMMPPTTRROOLL
KK878700
WWOORRKKPPIIEECCEE
WWOORRKKCCLLAAMMPP
TTIIGGTTOORCRCHH
KK22226666--11KKIITT
((IINCNCLLUDUDESES WWOORRKKCCLLAAMMPP,,
AADDAPAPTTEERR,,AANDND RREEGGUULLAATTOORR))
TTOOPPOOSSIITTIIVEVE ((++))SSTTUUDD
TTOORREEMMOOTTEECCOONNTTRROOLL
R
REECCEPEPTTAACCLLEE
U
USESERRIINNTTEERRFFAACCEE
CCOONNTTRROOLLPAPANNEELL
KK30300101--22
G
GAASSSSOOLLEENNOOIIDDKKITIT
((IINNSSIIDDEEMMAACHCHIINNEE))
KK22828255--11
TTOONNEEGGAATTIIVEVE ((--))SSTTUUDD
TIG WITH S-SERIES USER INTERFACE
FIGURE A.2

A-6
INSTALLATION
POWER WAVE®S500
SMAW (STICK) WELDING
Similar to TI welding a user interface is required for
adjusting the Stick welding settings. A Power Feed
wire feeder can be used as the user interface, or a
K3001-2 (user interface control panel) can be installed
into the power source (Figure A.3). The connection
diagram shown is based on the S-Series user inter-
face (K3001-2). In this diagram the remote control box
is optional.
REMOTE CONTROL BOX
K857
TO POSITIVE (+) STUD
TO REMOTE CONTROL
RECEPTACLE
TO NEGATIVE (-) STUD
ELECTRODE HOLDER KIT
K2394-1 KIT
(INICLUDES GROUND CLAMP)
WORK PIECE
WORK CLAMP
USER INTERFACE
CONTROL PANEL
K3001-2
STICK WITH S-SERIES USER INTERFACE
FIGURE A.3

A-7
INSTALLATION
POWER WAVE®S500
GMAW (MIG) WELDING
An arclink compatible wire feeder is recommended for
Mig welding. Refer to Figure A.4 for the connection
details.
RREEGGUULLAATTOORR
FFLLOOWWMMEETTEERR
GGASAS HHOOSSEE
WWOORRKKPPIIEECCEE
WWOORRKKCCLLAAMMPP
TTOOPPOOSSIITTIIVEVE ((++))SSTTUUDD
TTOONNEEGGAATTIIVEVE ((--))SSTTUUDD
PPFF1010--MM
WWIIRREEFFEEEEDDEERR
A
ARCRCLLIINNKKCCAABBLLEE
KK11554433--[[XXXX]]
MIG PROCESS
FIGURE A4

RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING
Connect the electrode and work cables between the
appropriate output studs of the POWER WAVES500
per the following guidelines:
• Most welding applications run with the electrode
being positive (+). For those applications, connect
the electrode cable between the wire drive feed plate
and the positive (+) output stud on the power source.
Connect a work lead from the negative (-) power
source output stud to the work piece
• When negative electrode polarity is required, such
as in some Innershield applications, reverse the out-
put connections at the power source (electrode cable
to the negative (-) stud, and work cable to the posi-
tive (+) stud).
Negative electrode polarity operation WIT OUT
use of a remote work sense lead (21) requires the
Negative Electrode Polarity attribute to be set. See
the Remote Sense Lead Specification section of
this document for further details.
-----------------------------------------------------------------------
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard
“SAFETY INFORMATION” located in the front of this
Instruction Manual.
General Guidelines
• Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive volt-
age drops caused by undersized welding cables and
poor connections often result in unsatisfactory weld-
ing performance. 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 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
loop area and therefore the inductance of the weld
circuit.
• Always weld in a direction away from the work
(ground) connection.
Table A.1 shows copper cable sizes recommended for
different currents and duty cycles. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable drop.
CAUTION
Amperes
200
250
300
350
400
450
500
550
Percent Duty
Cycle
100
100
100
100
100
100
60
40
0 to 50 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
50 to 100 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
100 to 150 Ft.
2
1
2/0
3/0
3/0
4/0
3/0
3/0
150 to 200 Ft.
1
1
2/0
3/0
3/0
4/0
3/0
3/0
200 to 250 Ft.
1/0
1/0
3/0
4/0
4/0
2-3/0
4/0
4/0
CABLE SIZES FOR COMBINED LEN THS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]**
OUTPUT CABLE GUIDELINES (Table A.1)
** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may
require cables larger than recommended, or cables rated higher than 167°F (75°C).
A-8
INSTALLATION
POWER WAVE®S500

FIGURE A.5
B
A
C
WORK
POWER
WAVE
S500
CABLE INDUCTANCE AND ITS
EFFECTS ON WELDING
Excessive cable inductance will cause the welding
performance to degrade. There are several factors
that contribute to the overall inductance of the cabling
system including cable size, and loop area. The loop
area is defined by the separation distance between
the electrode and work cables, and the overall welding
loop length. The welding loop length is defined as the
total of length of the electrode cable (A) + work cable
(B) + work path (C) (See Figure A.5).
To minimize inductance always use the appropriate
size cables, and whenever possible, run the electrode
and work cables in close proximity to one another to
minimize the loop area. Since the most significant fac-
tor in cable inductance is the welding loop length,
avoid excessive lengths and do not coil excess cable.
For long work piece lengths, a sliding ground should
be considered to keep the total welding loop length as
short as possible.
REMOTE SENSE LEAD
SPECIFICATIONS
Voltage Sensing Overview
The best arc performance occurs when the POWER
WAVE®S500 has accurate data about the arc condi-
tions.
Depending upon the process, inductance within the
electrode and work cables can influence the voltage
apparent at the studs of the welder, and have a dra-
matic effect on performance. Remote voltage sense
leads are used to improve the accuracy of the arc volt-
age information supplied to the control pc board.
Sense Lead Kits (K940-xx) are available for this pur-
pose.
The POWER WAVE®S500 has the ability to automati-
cally sense when remote sense leads are connected.
With this feature there are no requirements for setting-
up the machine to use remote sense leads. This fea-
ture can be disabled through the Weld Manager Utility
(available at www.powerwavesoftware.com) or
through the set up menu (if a user interface is installed
into the power source).
If the auto sense lead feature is disabled and
remote voltage sensing is enabled but the sense
leads are missing or improperly connected
extremely high welding outputs may occur.
------------------------------------------------------------------------
General Guidelines for Voltage Sense Leads
Sense leads should be attached as close to the weld
as practical, and out of the weld current path when
possible. In extremely sensitive applications it may be
necessary to route cables that contain the sense leads
away from the electrode and work welding cables.
Voltage sense leads requirements are based on the
weld process (See Table A.2)
CAUTION
Process
MAW
MAW-P
FCAW
TAW
SMAW
Electrode Voltage Sensing (1)
67 lead
67 lead required
67 lead required
67 lead required
Voltage sense at studs
Voltage sense at studs
Work Voltage Sensing (2)
21 lead
21 lead optional (3)
21 lead optional (3)
21 lead optional (3)
Voltage sense at studs
Voltage sense at studs
TABLE A.2
(1) The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin arclink control cable (K1543-
xx).
(2) When a work voltage sense lead (21) is connected the power source will automatically switch over to using this feedback (if the auto
sense feature is enable).
(3) Negative polarity semi-automatic process operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode
Polarity attribute to be set.
A-9
INSTALLATION
POWER WAVE®S500

Electrode Voltage Sensing
The remote ELECTRODE sense lead (67) is built into
the 5-pin arclink control cable and is always connect-
ed to the wire drive feed plate when a wire feeder is
present. Enabling or disabling electrode voltage sens-
ing is application specific, and automatically config-
ured by the active weld mode.
If the auto sense lead feature is disabled and the
weld polarity attribute is improperly configured
extremely high welding outputs may occur.
------------------------------------------------------------------------
Work Voltage Sensing
While most applications perform adequately by sens-
ing the work voltage directly at the output stud, the
use of a remote work voltage sense lead is recom-
mended for optimal performance. 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 the weld as practical,
but out of the weld current path. For more information
regarding the placement of remote work voltage
sense leads, see in this section entitled "Voltage
Sensing Considerations for Multiple Arc Systems."
Negative Electrode Polarity
The POWER WAVE®S500 has the ability to automati-
cally sense the polarity of the sense leads. With this
feature there are no set-up requirements for welding
with negative electrode polarity. This feature can be
disabled through the Weld Manager Utility (available
at www.powerwavesoftware.com) or through the set
up menu (if a user interface is installed into the power
source).
A-10
INSTALLATION
POWER WAVE®S500
CAUTION

VOLTAGE SENSING
CONSIDERATIONS FOR MULTIPLE
ARC SYSTEMS
Special care must be taken when more than one arc
is welding simultaneously on a single part. Multiple arc
applications do not necessarily dictate the use of
remote work voltage sense leads, but they are strong-
ly recommended.
If Sense Leads ARE NOT Used:
• Avoid common current paths. Current from adja-
cent arcs can induce voltage into each others cur-
rent paths that can be misinterpreted by the power
sources, and result in arc interference.
If Sense Leads 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 paths that
can be misinterpreted by the power sources, and
result in arc interference.
• For longitudinal applications, connect all work leads
at one end of the weldment, and all of the work volt-
age sense leads at the opposite end of the weld-
ment. Perform welding in the direction away from
the work leads and toward the sense leads.
(See Figure A.6)
DIRECTION
O F TRA VEL
CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.
CONNECT ALL SENSE
LEADS AT THE END
OF THE WELD.
FIGURE A.6
A-11
INSTALLATION
POWER WAVE®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.
(See Figure A.7)
A-12
INSTALLATION
POWER WAVE®S500
POWER
SOURCE
#2
POWER
SOURCE
#1
POWER
POWER
SOURCE
SOURCE
#1
POWER
SOURCE
#2
#2
POWER
SOURCE
#1
FIGURE A.7

CONTROL CABLE CONNECTIONS
General Guidelines
enuine Lincoln control cables should be used at all
times (except where noted otherwise). Lincoln cables
are specifically designed for the communication and
power needs of the Power Wave®/ Power Feed™sys-
tems. Most are designed to be connected end to end
for ease of extension. enerally, it is recommended
that the total length not exceed 100ft. (30.5m). The
use of non-standard cables, especially in lengths
greater than 25 feet, can lead to communication prob-
lems (system shutdowns), poor motor acceleration
(poor arc starting), and low wire driving force (wire
feeding problems). Always use the shortest length of
control cable possible, and DO NOT coil excess
cable.
Regarding cable placement, best results will be
obtained when control cables are routed separate
from the weld cables. This minimizes the possibility of
interference between the high currents flowing
through the weld cables, and the low level signals in
the control cables. These recommendations apply to
all communication cables including ArcLink®and
Ethernet connections.
Product specific Installation Instructions
Connection Between Power Source and ArcLink®
Compatible Wirefeeders (K1543, K2683 – ArcLink
Control Cable)
The 5-pin ArcLink control cable connects the power
source to the wire feeder. The control cable consists
of two power leads, one twisted pair for digital com-
munication, and one lead for voltage sensing. The 5-
pin ArcLink connection on the Power Wave®S500 is
located on the rear panel (See Case Back Controls in
the Operation Section). The control cable is keyed
and polarized to prevent improper connection. Best
results will be obtained when control cables are routed
separate from the weld cables, especially in long dis-
tance applications. The recommended combined
length of the ArcLink control cable network should not
exceed 200ft. (61.0m).
Connection Between Power Source and Ethernet
Networks
The POWER WAVE®S500 is equipped with an IP67
rated ODVA compliant RJ-45 Ethernet connector,
which is located on the rear panel. All external
Ethernet equipment (cables, switches, etc.), as
defined by the connection diagrams, must be supplied
by the customer. It is critical that all Ethernet cables
external 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 transmis-
sion. For best results, route Ethernet cables away
from weld cables, wire drive control cables, or any
other current carrying device that can create a fluctu-
ating magnetic field. For additional guidelines refer to
ISO/IEC 11801. Failure to follow these recommenda-
tions can result in an Ethernet connection failure dur-
ing welding.
A-13
INSTALLATION
POWER WAVE®S500

B-1
OPERATION
POWER WAVE®S500
• ELECTRIC S OCK CAN KILL.
• Do not touch electrically live
part or electrode with skin or
wet clothing.
• Insulate yourself from work and
ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards
removed or open.
---------------------------------------------------------------------
• FUMES AND GASSES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
---------------------------------------------------------------------
• WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
---------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body protec-
tion.
---------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN T E FRONT OF T IS OPERATING MAN-
UAL.
---------------------------------------------------------------------
WARNING
SAFETY PRECAUTIONS
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MAC INE.
POSITIVE OUTPUT
NEGATIVE OUTPUT
STATUS
PROTECTIVE
GROUND
COOLER
WARNING OR
CAUTION
GRAP IC SYMBOLS T AT APPEAR ON
T IS MAC INE OR IN T IS MANUAL
IG TEMPERATURE
OUTPUT
OPERATORS
MANUAL
CIRCUIT BREAKER
WORK
DANGEROUS
VOLTAGE
POWER-UP SEQUENCE
When the POWER WAVE®S500 is powered up, it can
take as long as 30 seconds for the machine to be
ready to weld. During this time period the user inter-
face will not be active.
DUTY CYCLE
The duty cycle is based on a ten-minute period. A
40% duty cycle represents 4 minutes of welding and 6
minutes of idling in a ten-minute period. Refer to the
technical specification section for the POWER WAVE®
S500’s duty cycle ratings.