Lincoln Electric IM10133 User Manual

Operator’s Manual

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POWER WAVE ®R500

For use with machines having Code Numbers:

11890

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Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10133 | Issue D ate Oct- 13

© Lincoln Global, Inc. All Rights Reserved.

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

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.

WARNING

This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.

CAUTION

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 Material Safety

Data Sheet (MSDS) 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 de velop 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

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.

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.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.

The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.

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.

SAFETY

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

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.

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 pos­sible to the area being welded.

2.d.5. Do not work next to welding power source.

3

SAFETY

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

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.

between the

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

with electrodes which require special ventilation
such as stainless or hard facing (see instructions
on container or MSDS) 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. In confined spaces or in
some circumstances, outdoors, a respirator may
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.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

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
material safety data sheet (MSDS) and follow your employer’s
safety practices. MSDS forms are available from your welding
distributor or from the manufacturer.

5.f. Also see item 1.b.

4

cause

SAFETY

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.

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 1235 Jefferson Davis
Highway, Arlington, VA 22202.

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.

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.

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.

Welding Safety
Interactive Web Guide
for mobile devices

5

TABLE OF CONTENTS

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 Ground Connections ...... .....................................................................................A-3

Machine Grounding ..............................................................................................................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 MIG Process.......................................................................................A-5

Recommended Work Cable Sizes .......................................................................................A-6

Cable Inductance and its Effects on Welding.......................................................................A-7

Remote Sense Lead Specifications..............................................................................A-7, A-8

Voltage Sensing Considerations for Multiple Arc System...........................................A-9, A-10

Control Cable Connections .......................................................................................................A-11

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Power-Up Sequence .....................................................................................................B-1

Duty Cycle.....................................................................................................................B-1

Graphic 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

________________________________________________________________________________

vivi

Accessories .....................................................................................................Section C

Kits, Options / Accessories....................................................................................C-1

Field Installed Options...........................................................................................C-1

Stick Operations ....................................................................................................C-1

________________________________________________________________________

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 Guide.......................................................................E-1

Using Status LED, Error Fault Codes and Input Control Board....................................E-2, E-4

Troubleshooting Guide.............................................................................E-5 thru E-8

________________________________________________________________________________

Wiring Diagram and Dimension Print ............................................................Section F

________________________________________________________________________

Parts Pages ...............................................................................................................P-710 Series

_______________________________________________________________________

________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE®R500

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K3169-1

VOLTAGE/PHASE/

FREQUENCY

Duty Cycle

40% rating

100% rating

INPUT

Input Voltage ± 10%

208/230/400*460/575

50/60 Hz

(includes 380V to 415V)

GMAW

40%

60%

100%

Input Amperes

80/73/41/37/29

60/54/30/27/21

RATED OUTPUT

SMAW

40%

60%

100%

Idle Power

500 Watts Max.

(fan on)

GTAW-DC

40%

Power Factor @

Rated Output

.95

60%

100%

A-1

200-208/3/50/60

230/3/50/60

380-415/3/50/60

460/3/50/60
575/3/50/60

550 Amps

41.5 Volts

500 Amps

39 Volts

450 Amps

36.5 Volts

550 Amps

42 Volts

500 Amps

40 Volts

450 Amps

38 Volts

550 Amps

32 Volts

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT

VOLTAGE / PHASE/

FREQUENCY

200-208/3/50/60

230/3/50/60

380-415/3/50/60

460/3/50/60
575/3/50/60

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 at effective current rating of unit.

MAXIMUM INPUT

AMPERE RATING AND

DUTY CYCLE

80A, 40%
73A, 40%
41A, 40%
37A, 40%
29A, 40%

CORD SIZE

AWG SIZES

(mm

4 (21)
4 (21)
8 (10)
8 (10)
10 (7)

3

2

)

TIME DELAY FUSE

500 Amps

30 Volts

1

OR BREAKER

AMPERAGE

100

90
60
45
35

450 Amps

28 Volts

2

POWER WAVE®R500

A-2

MODEL

PROCESS

GMAW

GMAW-Pulse

FCAW

GTAW-DC

HEIGHT

INSTALLATION

WELDING PROCESS

OUTPUT RANGE (AMPERES)

40-550A

5-550A

PHYSICAL DIMENSIONS

WIDTH

OCV (Uo)

Mean Peak

70V 73V

24V 36V

DEPTH

A-2

WEIGHT

K3169-1

22.45 in ( 570 mm)

14.00in ( 356 mm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

Environmentally Hardened: -4°F to 104°F (-20C to 40C)

IP23 155º(F) Insulation Class

* Weight does not include input cord.

24.80in ( 630mm)

STORAGE TEMPERATURE RANGE

Environmentally Hardened: -40°F to 185°F (-40C to 85C)

150 lbs (68 kg)

*

Thermal tests have been performed at ambient tem­perature. The duty cycle (duty factor) at 40°C has
been determined by simulation.

POWER WAVE®R500

A-3

INSTALLATION

A-3

SAFETY PRECAUTIONS Read this

entire installation section before you start installa-

tion.

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• Turn the input power OFF at the

disconnect switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding system
at the disconnect switch or fuse box before work­ing on the equipment.

• Do not touch electrically hot parts.

• Always connect the POWER WAVE
grounding lug to a proper safety (Earth) ground.

-------------------------------------------------------------

®

R500

SELECT SUITABLE LOCATION

The POWER WAVE®R500 will operate in harsh envi­ronments. Even so, it is important that simple preven­tative measures are followed in order to assure long
life and reliable operation.

LIFTING

Both handles should be used when lifting POWER

®

WAVE
a lifting strap should be connected to both handles.
Do not attempt to lift the POWER WAVE
accessories attached to it.

R500. When using a crane or overhead device

®

R500 with

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when
lifting.

• Do not operate machine while
suspended when lifting.

FALLING

EQUIPMENT can

cause injury.

-------------------------------------------------------------

STACKING

The POWER WAVE®R500 cannot be stacked.

TILTING

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.

• 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 nor­mal 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
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.

®

R500 over com-

INPUT AND GROUND CONNECTIONS

Only a qualified electrician should connect the
POWER WAVE
accordance with the appropriate National Electrical
Code, all local codes and the information in this man­ual.

®

R500. Installation should be made in

MACHINE GROUNDING

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 prop­er grounding methods.

HIGH FREQUENCY PROTECTION

Locate the POWER WAVE®R500 away from radio
controlled machinery. The normal operation of the
POWER WAVE
ation of RF controlled equipment, which may result in
bodily injury or damage to the equipment.

®

R500 may adversely affect the oper-

POWER WAVE®R500

A-4

INSTALLATION

A-4

WARNING

Only a qualified electrician should
connect the input leads to the

POWER WAVE

®

R500. Connections
should be made in accordance with
all local and national electrical

codes and the connection diagrams. Failure to do
so may result in bodily injury or death.

------------------------------------------------------------------------

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 dia­grams 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 FIGURE A.1)
TO A PROPER SAFETY (EARTH) GROUND.

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 cir­cuit 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®R500 automatically adjusts to
work with different input voltages. No reconnect switch
settings are required.

WARNING

The POWER WAVE
switch is not intended as a service
disconnect for this equipment. Only
a qualified electrician should con­nect the input leads to the POWER

®

WAVE

R500. Connections should
be made in accordance with all local and national
electrical codes and the connection diagram locat­ed on the inside of the reconnect access door of
the machine. Failure to do so may result in bodily
injury or death.

®

R500 ON/OFF

INPUT CORD STRAIN RELIEF

ROUTE INPUT CORD
THROUGH RELIEF AND

TWIST NUT TO TIGHTEN

------------------------------------------------------------------------

FIGURE A.1

GROUND CONNECTION

CONNECT GROUND LEAD PER LOCAL

AND NATIONAL ELECTRIC CODE

POWER CONNECTION BLOCK

CONNECT EACH PHASE OF A THREE-PHASE

CONDUCTOR HERE

POWER WAVE®R500

INPUT POWER
ACCESS DOOR

A-5

REGULATOR
FLOWMETER

GASAS HHOSE

WORK PPIECE

WORK CCLAMP

TO PPOSITIVEVE ((+) SSTUD

TO NNEGATIVEVE ((-) SSTUD

PF1010-M

WIRE F FEEEEDER

ARCRCLINK CCABLE
K1543-[XX]

INSTALLATION

GMAW (MIG) WELDING

An arclink compatible wire feeder is recommended for
Mig welding. Refer to Figure A.3 for the connection
details.

FIGURE A.3

MIG PROCESS

A-5

POWER WAVE®R500

A-6

INSTALLATION

A-6

RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING

Connect the electrode and work cables between the

®

appropriate output studs of the
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 out­put connections at the power source (electrode cable
to the negative (-) stud, and work cable to the posi­tive (+) stud).

POWER WAVE

R500

CAUTION

Negative electrode polarity operation WITHOUT
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 elec­trode 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 weld­ing 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.

OUTPUT CABLE GUIDELINES (Table A.1)

Percent Duty

Amperes

200

250

300

350

400

450

500

550

** 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).

Cycle

100

100

100

100

100

100

60

40

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED
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

167°F (75°C)]**

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

POWER WAVE®R500

A-7

INSTALLATION

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 fac­tor 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
tions.

R500 has accurate data about the arc condi-

TABLE A.2

Process

Electrode Voltage Sensing

67 lead

A-7

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 dra­matic effect on performance. Remote voltage sense
leads are used to improve the accuracy of the arc volt­age information supplied to the control pc board.
Sense Lead Kits (K940-xx) are available for this pur­pose.

The POWER WAVE

®

R500 has the ability to automati­cally sense when remote sense leads are connected.
With this feature there are no requirements for setting­up the machine to use remote sense leads. 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).

CAUTION

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)

(1)

Work Voltage Sensing

21 lead

(2)

GMAW

GMAW-P

FCAW
GTAW

(1)

The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin arclink control cable (K1543­xx).

(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.

67 lead required
67 lead required
67 lead required

Voltage sense at studs

21 lead optional
21 lead optional
21 lead optional

Voltage sense at studs

(3)

(3)

(3)

FIGURE A.5

POWER
WAVE
R500

B

A

C

WORK

POWER WAVE®R500

A-8

Electrode Voltage Sensing

The remote ELECTRODE sense lead (67) is built into
the 5-pin arclink control cable and is always connect­ed to the wire drive feed plate when a wire feeder is
present. Enabling or disabling electrode voltage sens­ing is application specific, and automatically config­ured by the active weld mode.

INSTALLATION

CAUTION

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 sens­ing the work voltage directly at the output stud, the
use of a remote work voltage sense lead is recom­mended 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."

A-8

Negative Electrode Polarity

®

The POWER WAVE
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).

R500 has the ability to automati-

POWER WAVE®R500

A-9

INSTALLATION

A-9

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 strong­ly recommended.

If Sense Leads ARE NOT Used:

• Avoid common current paths. 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.

FIGURE A.6

DIRECTION
OF TR A VEL

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 volt­age sense leads at the opposite end of the weld­ment. Perform welding in the direction away from
the work leads and toward the sense leads.

(See Figure A.6)

CONNECT ALL SENSE
LEADS AT THE END
OF THE WELD.

CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.

POWER WAVE®R500

A-10

INSTALLATION

• 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)

FIGURE A.7

POWER

SOURCE

#1

WER

PO
SOURCE

#2

A-10

POWER
SOURCE
#1

WER

PO
SOURCE

#1

POWER
SOURCE

#2

WER

PO

SOURCE

#2

POWER WAVE®R500

A-11

INSTALLATION

A-11

CONTROL CABLE CONNECTIONS

General Guidelines

Genuine 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
tems. Most are designed to be connected end to end
for ease of extension. Generally, 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 prob­lems (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
Ethernet connections.

/ Power Feed™sys-

®

and

Connection Between Power Source and Ethernet
Networks

®

The POWER WAVE

R500 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 transmis­sion. 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 recommenda­tions can result in an Ethernet connection failure dur­ing welding.

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 com­munication, and one lead for voltage sensing. The 5-

®

pin ArcLink connection on the Power Wave

R500 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 dis­tance applications. The recommended combined
length of the ArcLink control cable network should not
exceed 200ft. (61.0m).

®

POWER WAVE®R500

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK 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.

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

WARNING OR
CAUTION

DANGEROUS
VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

HIGH TEMPERATURE

STATUS

---------------------------------------------------------------------

ARC RAYS can burn.

Wear eye, ear and body protec-

•
tion.

---------------------------------------------------------------------

SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE
UAL.

---------------------------------------------------------------------

FRONT OF THIS OPERATING MAN-

POWER-UP SEQUENCE

When the POWER WAVE®R500 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
R500ʼs duty cycle ratings.

PROTECTIVE
GROUND

COOLER

OUTPUT

OPERATORS
MANUAL

WORK

CIRCUIT BREAKER

®

POWER WAVE®R500

B-2

OPERATION

B-2

PRODUCT DESCRIPTION

PRODUCT SUMMARY

The POWER WAVE
power source with high-end functionality capable of
Stick, DC TIG, MIG, Pulsed MIG and Flux-Cored
welding. It is ideal for a wide variety of materials
including aluminum, stainless, and nickel — where arc
performance is critical.

The POWER WAVE
flexible welding system. Like existing Power Waveʼs
the software based architecture allows for future
upgradeability. One significant change from the cur-

rent range of Power Wave
communication feature is standard on the POWER

®

WAVE

R500 which allows for effortless software
upgrades through Powerwavesoftware.com. The
Ethernet communication also gives the POWER

®

WAVE

R500 the ability to run Production

Monitoring™ 2. A Devicenet option allows the

POWER WAVE

configurations and the POWER WAVE
designed to be compatible with advanced welding
modules like STT.

®

R500 is a portable multi-process

®

R500 is designed to be a very

®

units is that the Ethernet

®

R500 to be used in a wide range of

®

R500 is

PROCESS LIMITATIONS

The software based weld tables of the POWER

®

WAVE

R500 limit the process capability within the
output range and the safe limits of the machine. In
general the processes will be limited to .030-.052 solid
steel wire, .030 -.045 stainless wire, .035 -1/16 cored
wire, and .035 - 1/16 Aluminum wire.

EQUIPMENT LIMITATIONS

®

Only ArcLink compatible semiautomatic wire feeders

,

and users interfaces may be used. If other Lincoln
wire feeders or non-Lincoln wire feeders are used
there will be limited process capability and perfor­mance and features will be limited.

RECOMMENDED PROCESSES AND
EQUIPMENT

The POWER WAVE®R500 is recommended for semiauto­matic welding, and may also be suitable for basic hard

automation applications. The POWER WAVE
set up in a number of configurations, some requiring option­al equipment or welding programs.

RECOMMENDED EQUIPMENT

The POWER WAVE®R500
and semiautomatic welding. The
can be set up in a number of configurations, some requiring

optional equipment or welding programs.

is recommended for robotic

POWER WAVE®R500

RECOMMENDED PROCESSES

The POWER WAVE®R500 is a high speed, multi­process power source capable of regulating the cur­rent, voltage, or power of the welding arc. With an out­put range of 5 to 550 amperes, it supports a number
of standard processes including synergic GMAW,
GMAW-P, FCAW, FCAW-SS, SMAW, GTAW and
GTAW-P on various materials especially steel, alu­minum and stainless.

®

R500 can be

POWER WAVE®R500

B-3

OPERATION

B-3

DESIGN FEATURES

Loaded with Standard Features

• Multiple process DC output range: 5 - 550 Amps

• 200 – 600 VAC, 3 phase, 50-60Hz input power

• New and Improved Line Voltage Compensation
holds the output constant over wide input voltage
fluctuations.

• Utilizes next generation microprocessor control,

®

based on the ArcLink

• State of the art power electronics technology yields
superior welding capability.

• Electronic over current protection

• Input over voltage protection.

• F.A.N. (fan as needed). Cooling fan only runs
when needed.

• Thermostatically protected for safety and reliability.

platform.

3. FEEDER STATUS LED - A two color LED that

indicates system errors. The Power Wave R500 is
equipped with two indicators. One is for the invert­er power source, while the other indicates the sta­tus of the feeder control system. Normal operation
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.)

NOTE: The Power Wave R500 status light will flash

green, and sometimes red and green, for up to one
minute when the machine is first turned on. This is a
normal situation as the machine goes through a self
test at power up.

4. POWER SWITCH - Controls power to the POWER

®

WAVE

5. NEGATIVE WELD OUTPUT

6. POSITIVE WELD OUTPUT

7. VOLTAGE SENSE CONNECTOR: Allows for sep-

arate remote electrode and work sense leads.

R500.

• Ethernet connectivity.

• Panel mounted Status and Thermal LED indicators
facilitate quick and easy troubleshooting.

• Potted PC boards for enhanced ruggedness/relia­bility.

• Enclosure reinforced with heavy duty aluminum
extrusions for mechanical toughness

• Waveform Control Technology™ for good weld
appearance and low spatter, even when welding
nickel alloys.

• Sync Tandem installed.

CASE FRONT CONTROLS

(See Figure B.1)

1. STATUS LED - (See Troubleshooting Section for

operational functions).

2. THERMAL LED - Indicates when machine has

thermal fault.

Pin Lead Function

3 21 Work Voltage Sense
1 67E Electrode Voltage Sense

FIGURE B.1

1

2

3

4

5

6

7

POWER WAVE®R500

B-4

OPERATION

CASE BACK CONTROLS

(See Figure B.2)

1. 115 VAC CIRCUIT BREAKER

2. 115 VAC RECEPTACLES

3. WIRE FEEDER RECEPTACLE

4. SYNC TANDEM/ STT CONNECTOR

5. ARCLINK CONNECTOR

6. DEVICENET KIT (OPTIONAL)

7. ETHERNET (SHIELDED)

8. 40V CIRCUIT BREAKER

9. I/O CONNECTOR

B-4

FIGURE B.2

8

1

7

2

9

3

4

5

6

POWER WAVE®R500

B-5

OPERATION

COMMON WELDING PROCEDURES

B-5

WARNING

MAKING A WELD
The serviceability of a product or structure utiliz­ing the welding programs is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
these programs. These variables include, but are
not limited to, welding procedure, plate chemistry
and temperature, weldment design, fabrication
methods and service requirements. The available
range of a welding program may not be suitable
for all applications, and the build/user is and must
be solely responsible for welding program selec­tion.

Choose the electrode material, electrode size, shield­ing gas, and process (GMAW, GMAW-P etc.) appro­priate for the material to be welded.

Select the weld mode that best matches the desired
welding process. The standard weld set shipped with

®

the POWER WAVE
range of common processes that will meet most
needs. If a special weld mode is desired, contact the
local Lincoln Electric sales representative.

R500 encompasses a wide

BASIC WELDING CONTROLS

Weld Mode

Selecting a weld mode determines the output charac-

teristics of the Power Wave

®

power source. Weld
modes are developed with a specific electrode materi­al, electrode size, and shielding gas. For a more com­plete description of the weld modes programmed into

®

the POWER WAVE

R500 at the factory, refer to the

Weld Set Reference Guide supplied with the machine
or available at www.powerwavesoftware.com.

Wire Feed Speed (WFS)

In synergic welding modes (synergic CV, GMAW-P),
WFS is the dominant control parameter. The user
adjusts WFS according to factors such as wire size,
penetration requirements, heat input, etc. The

®

POWER WAVE

R500 then uses the WFS setting to

adjust the voltage and current according to settings

®

contained in the POWER WAVE

.

In non-synergic modes, the WFS control behaves like
a conventional power source where WFS and voltage
are independent adjustments. Therefore, to maintain
proper arc characteristics, the operator must adjust
the voltage to compensate for any changes made to
the WFS.

All adjustments are made through the user interface.
Because of the different configuration options your
system may not have all of the following adjustments.
See Accessories Section for Kits and Options avali-

able to use with the POWER WAVE

®

R500.

DEFINITION OF WELDING MODES

NON-SYNERGIC WELDING MODES

• A Non-synergic welding mode requires all welding

process variables to be set by the operator.

SYNERGIC WELDING MODES

• A Synergic welding mode offers the simplicity of

single knob control. The machine will select the cor­rect voltage and amperage based on the Wire Feed
Speed (WFS) set by the operator.

Amps

In constant current modes, this control adjusts the
welding amperage.

Volts

In constant voltage modes, this control adjusts the
welding voltage.

Trim

In pulse synergic welding modes, the Trim setting
adjusts the arc length. Trim is adjustable from 0.50 to

1.50. 1.00 is the nominal setting and is a good start­ing point for most conditions.

UltimArc™ Control

UltimArc™ Control allows the operator to vary the arc
characteristics. UltimArc™ Control is adjustable from
–10.0 to +10.0 with a nominal setting of 0.0.

POWER WAVE®R500

B-6

OPERATION

B-6

SMAW (STICK) WELDING

The welding current and Arc Force settings can be set

™

through a Power Feed

10M or Power Feed™25M
wire feeder. Alternatively an optional Stick / TIG UI
can be installed into the power source to control these
settings locally.

In a SMAW (STICK mode), Arc Force can be adjust­ed. It can be set to the lower range for a soft and less
penetrating arc characteristic (negative numeric val­ues) or to the higher range (positive numeric values)
for a crisp and more penetrating arc. Normally, when
welding with cellulosic types of electrodes (E6010,
E7010, E6011), a higher energy arc is required to
maintain arc stability. This is usually indicated when
the electrode sticks to the work-piece or when the arc
becomes unstable during manipulative technique. For
low hydrogen types of electrodes (E7018, E8018,
E9018, etc.) a softer arc is usually desirable and the
lower end of the Arc Control suits these types of elec­trodes. In either case the arc control is available to
increase or decrease the energy level delivered to the
arc.

GTAW (TIG) WELDING

The welding current can be set through a Power

™

Feed

10M or Power Feed™25M wire feeder.
Alternatively an optional Stick / TIG UI can be installed
into the power source to control these settings locally.

The TIG mode features continuous control from 5 to
550 amps with the use of an optional foot amptrol.

®

The POWER WAVE

R500 can be run in either a

Touch Start TIG mode or Scratch start TIG mode.

CONSTANT VOLTAGE WELDING
Synergic CV

For each wire feed speed, a corresponding voltage is
preprogrammed into the machine through special soft­ware at the factory.

The nominal preprogrammed voltage is the best aver­age voltage for a given wire feed speed, but may be
adjusted to preference. When the wire feed speed

changes, the POWER WAVE

®

R500 automatically
adjusts the voltage level correspondingly to maintain
similar arc characteristics throughout the WFS range.

Non Synergic CV

In non-synergic modes, the WFS control behaves
more like a conventional CV power source where
WFS and voltage are independent adjustments.
Therefore to maintain the arc characteristics, the oper­ator must adjust the voltage to compensate for any
changes made to the WFS.

All CV Modes

Pinch adjusts the apparent inductance of the wave
shape. The “pinch” function is inversely proportional
to inductance. Therefore, increasing Pinch Control
greater than 0.0 results in a crisper arc (more spatter)
while decreasing the Pinch Control to less than 0.0
provides a softer arc (less spatter).

PULSE WELDING

Pulse welding procedures are set by controlling an
overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall
time and pulse frequency all affect the voltage. The
exact voltage 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)

FIGURE B.3

POWER WAVE®R500

B-7

OPERATION

Most pulse welding programs are synergic. As the

wire feed speed is adjusted, the POWER WAVE
R500 will automatically recalculate the waveform
parameters to maintain similar arc properties.

®

The POWER WAVE

R500 utilizes “adaptive control”
to compensate for changes in the electrical stick-out
while welding. (Electrical stick-out is the distance
from the contact tip to the work piece.) The POWER

®

WAVE

R500 waveforms are optimized for a 0.75”
stick-out. The adaptive behavior supports a range of
stick-outs from 0.50 to 1.25”. At very low or high wire
feed speeds, the adaptive range may be less due to
reaching physical limitations of the welding process.

UltimArc™ Control adjusts the focus or shape of the
arc. UltimArc™ Control is adjustable from -10.0 to
+10.0 with a nominal setting of 0.0. Increasing the
UltimArc™ Control increases the pulse frequency and
background current while decreasing the peak cur­rent. This results in a tight, stiff arc used for high
speed sheet metal welding. Decreasing the
UltimArc™ Control decreases the pulse frequency
and background current while increasing the peak cur­rent. This results in a soft arc good for out of position
welding. (See Figure B.4)

B-7

®

FIGURE B.4

POWER WAVE®R500

C-1

ACCESSORIES

C-1

KITS, OPTIONS AND ACCESSORIES

All Kits Options and Accessories are found on the
Web site: (www.lincolnelectric.com)

FACTORY INSTALLED

None Available

FIELD INSTALLED OPTIONS

GENERAL OPTIONS

DeviceNet Kit

®

Mounts inside the back of the POWER WAVE
Allows Devicenet objects to communicate with the

POWER WAVE

Order K2827-1

Work Voltage Sense Lead Kit

Required to accurately monitor voltage at the arc.

Order K940-XX Series
Order K1811-XX Series

Deluxe Adjustable Gas Regulator & Hose Kit

Accommodates CO
ders. Includes a cylinder pressure gauge, dual scale

flow gauge and 4.3 ft. (1.3 m) gas hose.

Order K586-1

®

R500.

, Argon, or Argon-blend gas cylin-

2

R500.

AWG #1 Coaxial Cables:
Order K2593-25 for 25 feet (7.6 m) cable length.
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable length.

Welding Fume Extractors

Lincoln offers a wide range of fume extraction environ­mental system solutions, ranging from portable sys­tems easily wheeled around a shop to shop-wide cen­tral systems servicing many dedicated welding sta­tions.

Request Lincoln publication E13.40
(See www.lincolnelectric.com)

K2149-1 Work Lead Package

K1842-10 10ft. Weld Power Cable

Coaxial Welding Cable

Optimum weld cables for minimizing cable inductance
and optimizing welding performance.

AWG 1/0 Coaxial Cables:
Order K1796-25 for 25 feet (7.6 m) cable length.
Order K1796-50 for 50 feet (15.2 m) cable length.
Order K1796-75 for 75 feet (22.9 m) cable length.
Order K1796-100 for 100 feet (30.5 m) cable length.

POWER WAVE®R500

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not operate with covers
removed.

• Turn off power source before
installing or servicing.

•Do not touch electrically hot
parts.

• Turn the input power to the welding power
source off at the fuse box before working in the
terminal strip.

• Only qualified personnel should install, use or
service this equipment.

------------------------------------------------------------------------

ROUTINE MAINTENANCE

Routine maintenance consists of periodically blowing
out the machine, using a low-pressure air stream, to
remove accumulated dust and dirt from the intake and
outlet louvers, and the cooling channels in the
machine.

D-1

PERIODIC MAINTENANCE

Calibration of the POWER WAVE®R500 is critical to
its operation. Generally speaking the calibration will
not need adjustment. However, neglected or improp­erly calibrated machines may not yield satisfactory
weld performance. To ensure optimal performance,
the calibration of output Voltage and Current should
be checked yearly.

CALIBRATION SPECIFICATION

Output Voltage and Current are calibrated at the fac­tory. Generally the machine calibration will not need
adjustment. However, if the weld performance
changes, or the yearly calibration check reveals a
problem, use the calibration section of the
Diagnostics Utility to make the appropriate adjust­ments.

The calibration procedure itself requires the use of a
grid, and certified actual meters for voltage and cur­rent. The accuracy of the calibration will be directly
affected by the accuracy of the measuring equipment
you use. The Diagnostics Utility includes detailed
instructions, and is available on the Service

Navigator CD or at www.powerwavesoftware.com.

POWER WAVE®R500

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This 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, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the welding power source before installation or changing
drive rolls and/or guides.

• Do not touch electrically live parts.

• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.

• Welding power source must be connected to system ground per the National Electrical Code or any
applicable local codes.

• Only qualified personnel should perform maintenance work.

------------------------------------------------------------------------------------------------------------------------------------------------------

Observe all additional Safety Guidelines detailed throughout this manual.

CAUTION

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

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

POWER WAVE®R500

E-2

TROUBLESHOOTING

E-2

USING THE STATUS LED TO
TROUBLESHOOT SYSTEM PROBLEMS

Not all of the POWER WAVE®R500 errors will be displayed
on the user interface (if it is installed). There are two status
lights that display error codes. If a problem occurs it is

Included in this section is information about the Status
Lights and some basic troubleshooting charts for both
machine and weld performance.

The status light for the main control board and input control
board are dual-color LEDʼs. Normal operation for each is
steady green.

important to note the condition of the status lights.

Therefore, prior to cycling power to the system, check
the power source status light for error sequences as

Error conditions are indicated in the following chart Table
E.1.

noted below.

There is one externally mounted status light located on the
case front of the machine. This status light corresponds to
the main control board and input control boardʼs status.

TABLE E.1

Light

Condition

Steady Green

Blinking Green

System OK. Power source is operational, and is communicating normally with all healthy peripheral equip-

Occurs during power up or a system reset, and indicates the POWER WAVE

ing) each component in the system. Normal for first 1-10 seconds after power is turned on, or if the system

Main control board status light and Input control board

ment connected to its ArcLink network.

configuration is changed during operation.

Meaning

®

R500 is mapping (identify-

Fast Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

Status LED off

Indicates Auto-mapping has failed

Non-recoverable system fault. If the Status lights are flashing any combination of red and green, errors are

present. Read the error code(s) before the machine is turned off.

Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits

are flashed in red with a long pause between digits. If more than one code is present, the codes will be sep-

arated by a green light. Only active error conditions will be accessible through the Status Light.

Error codes can also be retrieved with the Power Wave Manager Utility available at www.power-

wavesoftware.com). This is the preferred method, since it can access historical information contained in

the error logs.

To clear the active error(s), turn power source off, and back on to reset.

Not applicable.

Not applicable.

Not applicable.

CAUTION

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

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

POWER WAVE®R500

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

ERROR CODES FOR THE POWER WAVE®R500

The following is a partial list of possible error codes for the POWER WAVE®R500. For a complete listing consult
the Service Manual for this machine.

MAIN CONTROL BOARD ( “STATUS” LIGHT)

Error Code #

Indication

36 Thermal error

54 Secondary (Output) over current error

56 Chopper communication error

58 Primary Fault error

71 Secondary (Output) over power error

Other

Indicates over temperature. Usually accompanied by Thermal LED.
Check fan operation. Be sure process does not exceed duty cycle
limit of the machine

The long term average secondary (weld) current limit has been
exceeded. NOTE: The long term average secondary current limit is
325A (1 Phase) or 575A (3 Phase).

Indicates communication link between main control board and chop­per has errors. If cycling the input power on the machine does not
clear the error, contact the Service Department.

Review error code from input board status light or status beeper.
Most likely caused by an over power condition which caused an
under voltage on the primary bus. If cycling the input power on the
machine does not clear the error, contact the Service Department.

The long term secondary (Weld) power limit has been exceeded.
NOTE: The long term average secondary current limit is 25kw (3
Phase), 14kw (1 Phase).

Error codes that contain three or four digits are defined as fatal
errors. These codes generally indicate internal errors on the Power
Source Control Board. If cycling the input power on the machine
does not clear the error, contact the Service Department.

CAUTION

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

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

POWER WAVE®R500

E-4

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

INPUT CONTROL BOARD

Error Code # Indication Type

Instantaneous input current limit has been exceeded. Typically
331 Instantaneous Input Current
Limit

334 Startup Current Check Failure

335 Startup Voltage Check Failure

336 Thermal Fault

337 Precharge Timeout

338 Input Power Limit

341 Input Voltage Dropout
346 Transformer Primary
Overcurrent

347 Average Input Current Limit

349 Bus Undervoltage

Persistent errors require power to be cycled for the error to clear.
Temporary faults will go away on their own if the error condition is removed.

indicates short term power overload. If problem persists contact

Service Department.

Input current limit was exceeded during machine power-up. If

problem persists contact Service Department.

Input voltage was too high or too low during machine power-up.

Verify that the input voltage is between 200V and 650V.

Thermostat on primary module tripped. Typically caused by a fan

malfunction or blocked air vent.

The DC bus voltage was not charged to a certain level at end of

precharge. If problem persists contact Service Department.

The input power drawn by the machine exceeded a safe level. If

problem persists, contact the Service Department.

The input voltage momentarily dropped out. Check connections

and verify quality of input power.

Transformer current too high. Typically indicates short-term power

overload. If problem persists, contact the Serivce Department.

Average input current limit has been exceeded. Typically indicates

short term power overload. If problem persists contact Service

Department.

The DC bus voltage dropped below the allowable limit. If problem

persists, contact the Service Department.

E-4

Persistent

Persistent

Temporary

Temporary

Persistent

Persistent

Temporary

Persistent

Persistent

Temporary

WIRE DRIVE MODULE

Error Code #

81 Motor Overload

82 Motor Overcurrent

83 Shutdown #1

84 Shutdown #2

Long term average motor current limit has been exceeded.
Typically indicates mechanical overload of system. If problem con­tinues consider higher torque gear ratio (lower speed range).

Absolute maximum motor current level has been exceeded. This is
a short term average to protect drive circuitry.

The Shutdown inputs on the Power Wave R500 have been dis­abled. The presence of these errors indicates the Feed Head
Control PCB may contain the wrong operating software.

Indication

CAUTION

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

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

POWER WAVE®R500

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

Basic Machine Problems

E-5

RECOMMENDED

COURSE OF ACTION

Input fuses keep blowing

Machine will not power up (no lights)

1. Improperly sized input fuses.

2. Improper Weld Procedure requir­ing output levels in excess of
machine rating.

3. Major physical or electrical dam­age is evident when the covers
are removed.

1. No Input Power

2. Input voltage is too low or too
high.

1. Make sure fuses are properly
sized. See installation section of
this manual for recommended
sizes.

2. Reduce output current, duty
cycle, or both.

3. Contact your local authorized
Lincoln Electric Field Service
facility for technical assistance.

1. Make sure input supply discon­nect has been turned ON. Check
input fuses. Make certain that the
Power Switch (SW1) on the
power source is in the “ON” posi­tion.

2. Make certain that input voltage is
correct, according to the Rating
Plate located on the rear of the
machine.

Machine wonʼt weld, canʼt get any
output.

This problem will normally be
accompanied by an error code. See
“Status Light” section of this docu­ment for additional information.

Input voltage is too low or too high.

1.

2. Thermal Error.

3. Secondary current limit has been
exceeded. (see error 54)

3a. Input control board fault (see

input control board error status).

1. Make certain that input voltage is
correct, according to the Rating
Plate located on the rear of the
machine.

2. See “Thermal LED is ON” sec­tion.

3. Possible short in output circuit. If
condition persists, contact an
authorized Lincoln Electric Field
Service facility.

CAUTION

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

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

POWER WAVE®R500

E-6

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-6

Thermal LED is ON

Thermal LED is ON

“Real Time Clock” no longer func­tioning

General degradation of weld perfor­mance

Improper fan operation

Basic Machine Problems (Continued)

1. Improper fan operation.

2. Open thermostat circuit.

1. Control PC Board Battery.

Weld and Arc Quality Problems

1. Wire feed problem.

2. Cabling problems.

1. Check for proper fan operation.
Fan should run in a low speed
setting when the machine is idle
and in a high speed when the
output is triggered. Check for
material blocking intake or
exhaust louvers, or for excessive
dirt clogging cooling channels in
machine.

2. Check for broken wires, open
connections or faulty thermostats
in the thermostat circuit.

1. Replace the battery (Type:
BS2032)

1. Check for feeding problems.

2. Check for bad connections,
excessive loops in cable, etc.

NOTE: The presence of heat in the
external welding circuit indicates
poor connections or undersized
cables.

3. Loss of, or improper Shielding
Gas.

4. Verify weld mode is correct for
process.

5. Machine calibration.

3. Verify gas flow and type are cor­rect.

4.Select the correct weld mode for

the application.

5. The power source may require
calibration. (current, voltage,
WFS).

CAUTION

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

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

POWER WAVE®R500

E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Weld and Arc Quality Problems (Continued)

Wire burns back to tip at the end of
the weld.

TROUBLESHOOTING

POSSIBLE

CAUSE

1. Burnback Time

E-7

RECOMMENDED

COURSE OF ACTION

1. Reduce burnback time and/or
work point.

Machine output shuts down during a
weld.

Machine wonʼt produce full output.

Excessively long and erratic arc.

1. Secondary current limit has been
exceeded, and the machine shuts
down to protect itself.

2. System Fault

1. Input voltage may be too low, lim­iting output capability of the power
source.

2. The input may be single phase.

3. Machine calibration.

1. Wire feed problem.

1. Adjust procedure or reduce load
to lower current draw from the
machine.

2. A non-recoverable fault will inter­rupt welding. This condition will
also result in a status light blink­ing. See the Status Light section
for more information.

1. Make certain that the input voltage
is proper, according to the Rating
Plate located on the rear of the
machine.

2. Verify all 3 phases are present.

3. Calibrate secondary current and
voltage.

1. Check for feeding problems. Make
sure proper gear ratio has been
selected.

2. Loss of, or improper Shielding
Gas

3. Machine calibration.

2. Verify gas flow and type are cor­rect

3. Calibrate secondary current and
voltage.

CAUTION

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

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

POWER WAVE®R500

E-8

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Ethernet

RECOMMENDED

COURSE OF ACTION

E-8

Cannot Connect

1. Physical connection.

2. IP address information.

3. Ethernet Speed

1. Verify that the correct patch cable
or cross over cable is being used
(refer to local IT department for
assistance).

1a. Verify the cables are fully insert-

ed into the bulk head connector.

1b. The LED under the PC board

ethernet connector will be lit
when the machine is connected
to another network device.

2. Use the appropriate PC utility to
verify the correct IP address infor­mation has been entered.

2a. Verify no duplicate the IP

addresses exist on the network.

3. Verify that the network device
connected to the Power Wave is
either a 10-baseT device or a
10/100-baseT device.

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.

CAUTION

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

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

POWER WAVE®R500

F-1

ENHANCED DIAGRAM

DIAGRAMS

F-1

POWER WAVE®R500

NOTE: This diagram is for reference 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.

F-2

DIMENSION PRINT

F-2

A.01

L16215

18.35

24.76

13.94

27.43

22.45

6.00

POWER WAVE®R500

PARTS LIST FOR

POWER WAVE

P-710P-710

®

R500

This parts list is provided as an informative guide only.

This information was accurate at the time of printing. However, since these
pages are regularly updated in Lincoln Electricʼs official Parts Book (BK-34),

always check with your Lincoln parts supplier for the latest parts information.

POWER WAVE®R500

4

3

1

2

P-710-AP-710-A

POWER WAVE

®

R500

08-15-2012

P-710-A.1P-710-A.1

POWER WAVE®R500

For Code: 11890

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and
column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

Miscellaneous Items

PAGE NO.

CODE NO.

11890 1 1 1 1

P-710-B.2

1

Case Front Assembly

P-710-C

2

Base & Power Conversion

Assembly

P-710-D

3

Case Back Assembly

P-710-E

4

Roof Assembly

P-710-F

POWER WAVE

®

R500

08-15-2012

P-710-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-710-B.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

DESCRIPTION PART NO. QTY. 123456789

Wiring Harness (Primary) G7141 1 X

POWER WAVE

®

R500

08-15-2012

NOTES

POWER WAVE®R500

Case Front Assembly

2C

2D

2E

22

20

2B

2D

2E

3A

5A

5B

24

15B

15A

14A

26C

25C

31A

17A

31C

31D

16B

16A

1

19

6

P-710-CP-710-C

16B

16A

31C

31D

17A

31A

2B

2C

2D

2D

2E

22

2E

19

3A

5A

5B

15A

24

15B

14A

25C

26C

20

POWER WAVE

®

R500

08-15-2012

P-710-C.1

P-710-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Front Assembly (G7162-2), Includes: NSS 1X
1 Case Front G7110 1 X
2 LED Harness (Not Shown), Includes: M22487-1 1 X
2A LED Panel Mount Assembly (Not Shown) S23740-2 2 X
2B Yellow LED T13657-4FA 1 X
2C Bi-Color LED T13657-7H24 1 X
2D LED Lens - Clear, Includes: S23093-1 2 X
2E LED Retaining “O” Ring S23094-1 2 X
3A P.C. Board Mounting Bracket M22764 1 X
3B #10-24 HLN (Not Shown) T9187-13 4 X
5A Line Switch S20030-1 1 X
5B Switch Cover S25384-1 1 X
5C Lock Washer (Not Shown) T9695-1 2 X
5D #10-32 x .625 HHCS (Not Shown) CF000084 2 X
6 MOV Assembly S18491-3 1 X
14A Output Stud S16656-4 2 X
14B Thread Forming Screw (Not Shown) S9225-99 4 X
14C 1/2-13 Flange Nut (Not Shown) T3960 2 X
15A Snubber Assembly M20305-1 1 X
15B Snubber Mounting Bracket S28402-1 1 X
15C #10-24 HLN (Not Shown) T9187-13 2 X
16A PFC Control P.C. Board Assembly S28805-[ ] 1 X
16B #10-24 HLN T9187-13 4 X
17A Output Stud Cover G6864 2 X
17B Plain Washer (Not Shown) S9262-184 4 X
17C Thread Forming Screw (Not Shown) S9225-100 4 X
19 Nameplate (G7456-1) (Part of G7456 ) NSS 1X
20 Plug Button T10397-23 1 X
22 Plug Button T10397-3 1 X
24

Sq. Flange Female Receptacle (S2) (Part of G7142 Harness)

S18657 1 X
25A Plain Washer (Not Shown) S9262-80 1 X
25B Lock Washer (Not Shown) E106A-15 1 X
25C 1/2-13 x 1.00 HHCS CF000021 1 X
26A Plain Washer (Not Shown) S9262-80 1 X
26B Lock Washer (Not Shown) E106A-15 1 X
26C 1/2-13 x 1.00 HHCS CF000030 1 X
29 Thread Forming Screw (Not Shown) S9225-99 4 X
31A Cover Plate L15069 1 X
31B Self Tapping Screw (Not Shown) S9225-99 4 X
31C UI Trim G6529 1 X
31D Decal - UI Cover Plate G6601-1 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

NSS - Not Sold Separately

POWER WAVE

®

R500

08-15-2012

Base & Power Conversion Assembly

2

3B

8A

8B

8C

1A

4A

10A

14A

10E

10B

32

30A

31A

21A

23A

22

20

19A

18A

21B

4B

3A

9A

11A

9E

9B

9G

9H

9K

9K

P-710-DP-710-D

30A

8C

8B

8A

3B

2

4B

31A

3A

21A

23A

21B

20

18A

22

19A

10A

10E

32

1A

4A

14A

10B

9B

9H

9K

9G

9K

POWER WAVE

®

R500

9A

9E

11A

08-15-2012

P-710-D.1

P-710-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Base Assembly (G7164-2), Includes: NSS 1X
1A Base L15254 1 X
1B Thread Forming Screw (Not Shown) S9225-99 6 X
2 Base Extrusion M21251-2 2 X
3A Attachment Kit Bracket L15091 2 X
3B Thread Forming Screw S9225-99 4 X
3C Shakeproof Lock Washer (Not Shown) T9695-1 2 X
4A Mounting Foot S28070 4 X
4B 1/4-20 HHCS CF000013 4 X
4C Lock Washer (Not Shown) E106A-2 4 X
8A Corner Cap L13138 4 X
8B Plain Washer S9262-182 8 X
8C Thread Forming Screw S9225-100 8 X
9 Front Divider Panel Assembly, Includes: L16052 1 X
9A Front Divider Panel G7151 1 X
9B Output Choke Assembly L13270-4 1 X
9C Thread Forming Screw (Not Shown) S9225-99 4 X
9E 115V Supply Board Assembly G6571-[ ] 1 X
9F #10-24 HLN (Not Shown) T9187-13 4 X
9G Resistor S10404-137 1 X
9H #10-24 x 7.50 RHS CF000191 1 X
9J Lock Washer (Not Shown) E106A-1 1 X
9K Insulating Washer T4479-A 2 X
9L #10-24 HLN (Not Shown) T9187-13 2 X
10 Rear Divider Panel Assembly, Includes: L16053 1 X
10A Rear Divider Panel G5053 1 X
10B Chopper & Heatsink Assembly G7245 1 X
10C Plain Washer (Not Shown) S9262-27 4 X
10D #10-24 HLN (Not Shown) T9187-13 4 X
10E Input P.C. Board M22489-[ ] 1 X
10F Plain Washer (Not Shown) S9262-27 4 X
10G #10-24 HLN (Not Shown) T9187-13 4 X
10H #10-24 HLN (Not Shown) T9187-13 2 X
10J Thread Forming Screw (Not Shown) S9225-99 2 X
11A 40 VDC Bus Board L15732-[ ] 1 X
11B #10-24 HLN (Not Shown) T9187-13 4 X
14A Resistor S10404-127 1 X
14B Insulating Washer (Not Shown) T4479-A 2 X
14C Plain Washer (Not Shown) S9262-27 1 X
14D Lock Washer (Not Shown) T9695-1 1 X
14E #10-24 x 7.50 RHS (Not Shown) CF000191 1 X
18A Input Cable Cover L16032 1 X
18B #10-24 HLN (Not Shown) T9187-13 2 X
18C Thread Forming Screw (Not Shown) S9225-99 1 X
19A Baffle M22847 1 X
19B #10-24 HLN (Not Shown) T9187-13 2 X
20 Decal - Ground T13260-4 1 X
21A Mylar Insulation S28105 1 X
21B Terminal Block S20763-3 1 X
21C #8-32 x 1.25 RHS (Not Shown) CF000193 2 X
22 U-V-W Decal (G7456-2) (Part of G7456) NSS 1X

NSS - Not Sold Separately

POWER WAVE

®

R500

08-15-2012

P-710-D.2

P-710-D.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

23A Ground Lug S28841 1 X
23B 1/4-20 x .625 HHCS (Not Shown) CF000013 1 X
23C Lock Washer (Not Shown) T9695-17 1 X
30A Power Conversion Assembly G7150 1 X
30B Thread Forming Screw (Not Shown) S9225-99 5 X
30C Plain Washer (Not Shown) S9262-27 1 X
30D #10-24 HLN (Not Shown) T9187-13 1 X
31A Air Baffle M22895 1 X
31B #10-24 HLN (Not Shown) T9187-13 2 X
32 Input Board Cover M22908 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

POWER WAVE

®

R500

08-15-2012

NOTES

POWER WAVE®R500

Case Back Assembly

1A

2A

4A

9A

10A

15A

11B

11A

10B

13A

10C

8A

8A

12

16

8B

8B

5B

17

32

4B

2B

3

23A

24A

24C

5A

5D

P-710-EP-710-E

13A

1A

2A

2B

23A

8A

4B

8B

4A

5A

5D

5B

8A

10A

8B

17

32

24C

24A

10C

10B

11B

15A

9A

POWER WAVE

®

R500

16

11A

12

08-15-2012

P-710-E.1

P-710-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Back Assembly (G7163-2), Includes: NSS 1X
1A Fan Bracket G7186 1 X
1B #10-24 HLN (Not Shown) T9187-13 4 X
2A Fan Assembly M22853 3 X
2B Machine Screw CF000058 12 X
2C Plain Washer (Not Shown) S9262-3 12 X
2D Lock Washer (Not Shown) T4291-A 12 X
3 Rear Panel G5051-1 1 X
4A Cord Grip Connector S19999 1 X
4B Conduit Lock Nut T14370-3 1 X
5A Ethernet Connector M19969-9 1 X
5B Ethernet Cover M19969-4 1 X
5C Adapter Plate S25438-9 1 X
5D #10-24 HLN (Not Shown) T9187-13 2 X
6 Fan Harness (Not Shown) L15109-1 1 X
8A Circuit Breaker T12287-20 2 X
8B Sealing Boot S22061-3 2 X
9A Cover Plate S25438-3 1 X
9B #10-24 HLN (Not Shown) T9187-13 2 X
10A Receptacle S20184 1 X
10B Receptacle Cover M16996 1 X
10C Decal (115V Receptacle) M22176 2 X
10D Thread Forming Screw (Not Shown) S9225-100 2 X
10E #10-24 HLN (Not Shown) T9187-13 2 X
11 Plug & Lead Assembly (Sync Tandem), Includes: M21927-1 1 X
11A 6 Socket Connector S12021-79 1 X
1 1B Connector Adapter Plate S25438-2 1 X
11C Self Tapping Screw (Not Shown) S8025-96 2 X
11D #10-24 HLN (Not Shown) T9187-13 2 X
12 Connector Cap S17062-9 1 X
13A Brickwork Plate L15108-2 1 X
13B Thread Forming Screw (Not Shown) S9225-99 6 X
14 Plug & Lead Assembly (Devicenet), Includes: M22519 1 X
14A Connector (S3) (5 Socket) (Not Shown) S12021-73 1 X
14B Self Tapping Screw (Not Shown) S8025-118 2 X
15 Connector Cap S17062-10 1 X
16 Decal (CB) (G7456-4) (Part of G7456) NSS 1X
17 Receptacle Harness (Not Shown) L15110 1 X
18A Ground Reference (Not Shown) S26124 1 X
18B #10-24 HN (Not Shown) CF000010 2 X
18C Lock Washer (Not Shown) E106A-1 1 X
22 Suppressor Assembly (Not Shown) S18858-17 1 X
23 I/O Wiring Harness, Includes: L13418-2 1 X
23A Adapter Plate S28068-2 1 X
23B Header Plug (12 Pin) S24843-12 1 X
23C #10-24 HLN (Not Shown) T9187-13 2 X
24A Cover Plate S28547 1 X
24B Thread Forming Screw (Not Shown) S9225-99 2 X
24C Plug Button T10397-4 1 X
28 Thread Forming Screw (Not Shown) S9225-99 4 X

NSS - Not Sold Separately

POWER WAVE

®

R500

08-15-2012

Roof Assembly

2A

6A

7B

7C

7A

7D

7E

7F

7G

3A

10A

14

12A

13A

13B

13C

1A

1B

1C

16A

16B

5A

2B

5B

5C

8A

8B

8C

8E

8D

9C

P-710-FP-710-F

7F

7G

7E

3A

7C

16A

12A

7A

1B

16B

1A

1C

10A

14

6A

2A

2B

5A

7B

7D

13A

13C

13B

POWER WAVE

8A

®

8C

8E

R500

8B

5B

5C

9C

8D

08-15-2012

P-710-F.1

P-710-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Roof Assembly , Includes: L15724-1 1 X
1A Roof L12763-6 1 X
1B Warranty Decal (G7456-3) (Part of G7456) NSS 1X
1C Warning Decal L8064-1 1 X
1E Thread Forming Screw (Not Shown) S9225-99 2 X
2 Top Extrusion Assembly, Includes: M22375-2 1 X
2A Top Tray G5054 1 X
2B Top Extrusion M21251-1 2 X
2C Self Tapping Screw (Not Shown) S9225-99 7 X
2D #10-24 HLN (Not Shown) T9187-13 3 X
2E Thread Forming Screw (Not Shown) S9225-99 2 X
3A Handle Mounting Bracket L15070 2 X
3B Self Tapping Screw (Not Shown) S9225-100 8 X
5A Corner Cap L13138 4 X
5B Plain Washer S9262-182 12 X
5C Thread Forming Screw S9225-100 12 X
6A Input Choke Assembly L16139 1 X
6B Thread Forming Screw (Not Shown) S9225-99 2 X
6C #10-24 HN (Not Shown) CF000010 1 X
7 Left Case Side Assembly, Includes: M22781 1 X
7A Left Case Side L15257 1 X
7B Decal - Lincoln Logo S27368-4 1 X
7C Decal - Powerwave Logo S27468 1 X
7D Acoustical Foam M15045-110 2 X
7E Access Door M22907 1 X
7F Thread Forming Screw S9225-99 3 X
7G Warning Decal S20900 1 X
8 Right Case Side Assembly, Includes: M22782 1 X
8A Right Case Side L15258 1 X
8B Decal - Lincoln Logo S27368-4 1 X
8C Decal - Powerwave Logo S27468 1 X
8D Wiring Diagram G7188 1 X
8E Green Initiative Decal S28039-2 1 X
9A Plain Washer (Not Shown) S9262-182 4 X
9B Thread Forming Screw (Not Shown) S9225-100 4 X
9C Thread Forming Screw S9225-99 8 X
10A Countrol P.C. Board S22804-[ ] 1 X
10B #10-24 HLN (Not Shown) T9187-13 4 X
11 Label - Control P.C. Board (Not Shown) S28503 1 X
12A Wire Drive P.C. Board Assembly S28626-[ ] 1 X
12B #10-24 HLN (Not Shown) T9187-13 4 X
13A Voltage Sense Bracket M24649 1 X
13B Voltage Sense P.C. Board M19540-[ ] 1 X
13C Diode Bridge T13637-6 1 X
13D Plain Waswher (Not Shown) S9262-27 1 X
13E Lock Washer (Not Shown) E106A-1 1 X
13F #10-24 HN (Not Shown) CF000010 1 X
13G Thread Forming Screw (Not Shown) S9225-99 2 X
14 Ethernet Cable Assembly M19969-13 1 X
16A Handle G6525-3 2 X
16B Screw CF000410 8 X

NSS - Not Sold Separately

POWER WAVE

®

R500

08-15-2012

P-710-F.2

P-710-F.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

16C Lock Washer (Not Shown) E106A-27 8 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

POWER WAVE

®

R500

08-15-2012

NOTES

POWER WAVE®R500

NOTES

POWER WAVE®R500

NOTES

POWER WAVE®R500

CUSTOMER ASSISTANCE POLICY

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.