Lincoln Electric IM10144 User Manual

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POWER WAVE ® S700

For use with machines having Code Numbers:

11957

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10144 | Issue D ate Aug-13

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THANK YOU FOR SELECTING 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 AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

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

Gasoline Engines

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.

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.

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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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 customerʼs 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.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

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.

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications ...............................................................................................A-1, A-2

Safety Precautions ...............................................................................................................A-3

Suitable Location, Lifting ...............................................................................................A-3

Stacking ........................................................................................................................A-3

Tilting.............................................................................................................................A-3

Input and Ground Connections .....................................................................................A-3

Machine Grounding.......................................................................................................A-3

Input Connection ..................................................................................................................A-4

Input Fuse and Supply Wire..........................................................................................A-4

Input Voltage Selection .................................................................................................A-4

Reconnect Diagram..............................................................................................................A-5

High Frequency Protection............................................................................................A-5

System Overview and Connection Diagram.........................................................................A-5

Connection Diagram......................................................................................A-6 thru A-13

Recommended Work Cable Sizes ..............................................................................A-14

Output Cable Guidelines .............................................................................................A-15

Cable Inductance and its Effects on Welding..............................................................A-16

Remote Sense Lead Specifications ............................................................................A-16

Voltage Sensing Considerations for Multiple Arc Systems .........................................A-17

Circumferential Applications........................................................................................A-18

Control Cable Connections ................................................................................................A-19

________________________________________________________________________________

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

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

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

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

Graphic Symbols ...................................................................................................B-1, B-2

Product Description ..............................................................................................................B-3

Recommended Processes and Equipment, Equipment Limitations.....................................B-3

Basic Package

Robotic Feeder Control Cables and Adapters......................................................................B-4

Design Features ...................................................................................................................B-5

Case Front Controls .............................................................................................................B-5

Case Back Controls..............................................................................................................B-6

Common Welding Procedures................................................................................B-7 thru B-9

________________________________________________________________________________

, Sync Tandem Package, Common Optional Kits ........................................B-4

vivi

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

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

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

Power Wave Accessory Connection Scheme .......................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ...............................................................................................................D-1

Visual Inspection ..................................................................................................................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-3

Troubleshooting Guide...................................................................................E-4, E-5

________________________________________________________________________________

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

________________________________________________________________________

Parts Pages ...............................................................................................................P-721 Series

_______________________________________________________________________

________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER WAVE®S700

POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model

K3279-1

Process

Duty Cycle

100% rating

Input Voltage ± 10%

380-415/440-460/500/575

RATED OUTPUT

Duty Cycle

Amperes

Input Amperes

55/46/42/38

Volts at Rated

Amperes

Idle Power

(Watts)

205W Fan Off

(Max.)

360W Fan On

(Max.)

A-1

Power Factor @

Rated Output

.95

OCV

(U0)

GMAW

GMAW-P

GTAW

SMAW

FCAW-GS

FCAW-SS

RECOMMENDED INPUT WIRE AND FUSE SIZES

INPUT

VOLTAGE / 3 PHASE/

FREQUENCY

380/3/50 460/3/60 500/3/60 575/3/60

60%

100%

60%

100%

60%

100%

60%

100%

60%

100%

60%

100%

Maximum

Input Amperes

75 62 57 50

900A 700A

Type 75C

Copper Wire in

Conduit AWG

(IEC) Sizes 40C

(104°F) Ambient

6 (16) 6 (16) 8 (10) 8 (10)

44V

34V

44V

70V AVG.

78V PEAK

70V AVG.

78V PEAK

24V AVG.

27V PEAK

60V AVG.

67V PEAK

70V AVG.

78V PEAK

70V AVG.

78V PEAK

TIME DELAY FUSE

OR BREAKER

AMPERAGE

90 80 70 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.

POWER WAVE®S700

A-2

MODEL

CONFORMITY MARK

INSTALLATION

PHYSICAL DIMENSIONS

HEIGHT

WIDTH

DEPTH

A-2

WEIGHT

K3279-1

EN 60974-1

CSA C/US

30.10 in (76.5 cm)

19.1 in (48.5 cm)

36.7 in (93.2 cm)

TEMPERATURE RANGES

OPERATING TEMPERATURE RANGE

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

IP23 155º(F) Insulation Class

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

STORAGE TEMPERATURE RANGE

* An External filter will be required to meet CE or C-TICK conducted emission requirements.

Order K2444-4 filter kit to meet these requirements.

400 lbs (181 kg)

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

POWER WAVE®S700

A-3

INSTALLATION

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 ing lug (located inside the reconnect input access door) to a proper safety (Earth) ground.

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

S700 ground-

SUITABLE LOCATION

Location and ventilation for cooling

Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and front. Dirt, dust, or any foreign material that can be drawn into the welder should be kept at 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 shutdowns.

• Place the welder where clean cooling air can freely circulate in through the rear louvers and out through the case sides and front.

A-3

Environmental limitations

The Power Wave outdoor environment. The Power Wave not be subjected to falling water during use nor should any parts of it be submerged in water. Doing so may cause improper operation as well as pose a safety hazard. The best practice is to keep the machine in a dry, sheltered area.

• 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.

S700 is IP23 rated for use in an

S700 should

S700 over com-

LIFTING

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.

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

Lift the machine by the lift bail only. The lift bail is designed to lift the power source only. Do not attempt to lift the Power Wave sories attached to it.

S700 with acces-

STACKING

The Power Wave®S700 cannot be stacked.

• Dirt, dust, or any foreign material that can be drawn into the welder should be kept at 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 shutdowns.

• The best practice is to keep the machine in a dry, sheltered area.

POWER WAVE®S700

INPUT AND GROUND CONNECTIONS

Only a qualified electrician should connect the Power

Wave dance with the appropriate National Electrical Code, all local codes and the information in this manual.

S700. Installation should be made in accor-

MACHINE GROUNDING

The frame of the welder must be grounded. A ground terminal marked with the symbol shown is located inside the reconnect/input access door for this purpose.

See your local and national electrical codes for proper grounding methods.

A-4

INPUT CONNECTION

WARNING

INSTALLATION

INPUT FUSE AND SUPPLY WIRE CONSIDERATIONS

A-4

ELECTRIC SHOCK can kill.

Only a qualified electrician should connect the input leads to the

Power Wave

S700. Connections should be made in accordance with all local and national electrical codes and the connection diagrams located on the inside of the reconnect/input access door of the machine. Failure to do so may result in bodily injury or death.

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

(See Figure A.1)

Use a three-phrase supply line. A 1.75 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 two 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.

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

Welders are shipped connected for the highest input voltage listed on the rating plate. To move this connection to a different input voltage, see the diagram located on the inside of the input access door, also illustrated below. If the Auxiliary lead (indicated as ʻAʼ) is placed in the wrong position, there are two possible results. If the lead is placed in a position higher than the applied line voltage, the welder may not come on at all. If the Auxiliary lead is placed in a position lower than the applied line voltage, the welder will not come on, and the two circuit breakers in the reconnect area will open. If this occurs, turn off the input voltage, properly connect the auxiliary lead, reset the breakers, and try again

Input Power Compartment Controls Description:

. Input Contactor: Connects 3-phase power to the

welder.

2. Ground Lug: Provides an “Earth Ground” connec-

tion to the welder frame.

3. Auxiliary Reconnect: Allows for easy tap selection

on the auxiliary transformers over the range of input voltages.

4. Fuse: Protects the auxiliary transformers.

FIGURE A.1

POWER CONNECTION BLOCK

INPUT CORD STRAIN RELIEF

ROUTE INPUT CORD THROUGH RELIEF AND

TWIST NUT TO TIGHTEN

CONNECT EACH PHASE OF A THREE-PHASE

CONDUCTOR HERE

INPUT POWER ACCESS DOOR

GROUND CONNECTION

CONNECT GROUND LEAD PER LOCAL

AND NATIONAL ELECTRIC CODE

POWER WAVE®S700

A-5

RECONNECT DIAGRAM

INSTALLATION

A-5

INPUT SUPPLY CONNECTION DIAGRAM

WARNING

ELECTRIC

SHOCK

CAN KILL

VOLTAGE=380-415V

380-415V

440-460V

500V

550-575V

Do not operate with covers removed

Disconnect input power before servicing

Do not touch electrically live parts

Only qualified persons should install, use or service this equipment

VOLTAGE=440-460V

380-415V 380-415V 380-415V

'A'

440-460V

500V

550-575V

'A'

HIGH FREQUENCY PROTECTION

Locate the Power Wave®S700 away from radio controlled machinery. The normal operation of the Power

Wave

S700 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.

SYSTEM OVERVIEW AND CONNECTION DIAGRAM

W / L3

V / L2

U / L1

VOLTAGE=500V

440-460V

500V

550-575V

CR1

VOLTAGE=550-575V

440-460V

'A'

500V

550-575V

'A'

S26047

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.

GTAW (TIG) Welding

A user interface is required for adjusting the TIG welding settings. A Power Feed series wire feeder may also be used as a user interface. Refer to the connection diagrams for more connection information.

SMAW (Stick) Welding

A user interface is required for adjusting the stick welding settings. A Power Feed series wire feeder may also be used as a user interface. Refer to the connection diagrams for more connection information.

GMAW (MIG) Welding

An ArcLink compatible wire feeder is required for MIG welding.

POWER WAVE®S700

A-6

REGULATOR

FLOWMETER

HOSE

WORK

PIECE

WORK

CLAMP

POSITI

(+)

STUD

NEGATIVE

(-)

STUD

PF10-M

WIRE

EEDER

RCLINK

ABLE

43-[XX]

ONT

DOOR

BEEN

REMO

VED

SHOWN

ABLE

CONNECTIONS

INSTALLATION

A-6

MIG PROCESS

FIGURE A.2

BE AS

AB C

S (-

POWER WAVE®S700

AB C

H AS

( VE

EE F

A-7

INSTALLATION

STICK PROCESS

FIGURE A.3

TO NEGATIVE (-) STUD

FRONT DOOR HAS BEEN REMOVED

TO SHOWN CABLE CONNECTIONS.

A-7

K857

(OPTIONAL WITH K2320-1

REQUIRED FOR COMPATIBILITY)

REMOTE CONTROL BOX

WORK PIECE

WORK CLAMP

ELECTRODE HOLDER KIT

K2394-1 KIT

(INCLUDES GROUND CLAMP)

ARCLINK CABLE

TO POSITIVE (+) STUD

(K1543-XX)

PF10M WITH K2320-1

CONNECTION KIT

POWER WAVE®S700

(OPTIONAL)

A-8

INSTALLATION

TIG PROCESS

FIGURE A.4

FRONT DOOR HAS BEEN REMOVED

POWERWAVE S700

TO SHOWN CABLE CONNECTION S.

A-8

WORK PIECE

WORK CLAMP

TO POSITIVE (+) STUD

K870 FOOT AMPRTOL

TO NEGATIVE (-) STUD

TWO PIECE TIG TORCH

ARCLINK CABLE

K1543-(XX)

GAS HOSE

REGULATOR

FLOWMETER

WITH GAS VALVE.

POWER WAVE®S700

PF10-M WITH K2320-1 FOOT

AMPTROL CONNECTION KIT

A-9

INSTALLATION

MIG AND WATER COOLER PROCESS

FIGURE A.5

WORK PIECE

WORK CLAMP

A-9

FRONT DOOR HAS BEEN REMOVED

TO SHOWN CABLE CONNECTIONS

TO NEGATIVE (-) STUD

ARCLINK CABLE

K1543-[XX]

TO POSITIVE (+) STUD

MAGNUM WATER

COOLED GUN ASSEMBLY

GAS HOSE

REGULATOR

FLOWMETER

PF 10M

WIRE FEEDER

K1859-X

WATER HOSE KIT

COOL ARC 55

WATER COOLER

K590-X WATER

CONNECTION KIT

POWER WAVE®S700

A-10

INSTALLATION

SYNCHRONIZED TANDEM CONNECTION

FIGURE A.6

K3171-1 AUTODRIVE 19

TANDEM

WIRE DRIVE

CONTROL CABLE

(K1785-XX OR K2709-XX)

(K1543-XX)

ARCLINK CABLE

A-10

K3171-1 AUTODRIVE 19

TANDEM

POWER WAVE

S700

POWER WAVE

S700

WIRE DRIVE

CONTROL CABLE

M20979-1 SYNC

TANDEM CABLE

(K1785-XX OF K2709-XX)

(K1543-XX)

ARCLINK CABLE

POWER WAVE®S700

A-11

INSTALLATION

A-11

ROBOTIC SINGLE ARM PROCESS SETUP

FIGURE A.7

BACK OF POWER SOURCE

WORK SENSE

ETHERNET CONNECTION

LEAD CONNECTION

TO AUTODRIVE 19

ARCLINK CONNECTION

POWERWAVE S700

to show cable connections.

Front door has been removed

WORK CABLE(-)

K2163-XX or K1842-XX

AUTODRIVE

ELECTRODE CABLE (+)

K2163-XX or K1842-XX

ETHERNET CONNECTION

K1543-XX

ARCLINK CABLE

K940-25 OR K1811-XX

OPTIONAL WORK

SENSE LEAD KIT

WORK PIECE

WIRE FEEDER

(K1785-XX OF K2709-XX)

WIRE DRIVE

CONTROL CABLE

AUTODRIVE 19

CONTROLLER

K3004-1

ARCLINK IN

ARCLINK OUT

WIRE FEEDER

POWER WAVE®S700

A-12

INSTALLATION

ANALOG INTERFACE SETUP

FIGURE A.8

ANALOG INTERFACE

K1543-XXX

ARCLINK CONTROL

CABLE

A-12

WIRE DRIVE

K1785-XXX OR K2709-XX

AUTODRIVE 19

CONTROLLER

CONTROL CABLE

TO WIRE DRIVE

K1543-XXX

CABLE

ARCLINK CONTROL

POWER WAVE®S700

J1010A1

J15

10B1

J11

BT1

LED7

LED8

J12

J13

DIGITAL CCONTNTROL

4800

SERI

CONTROL

BOARD

REMOVE

THE

CREWS

FROM

FRONT

PAN

FOLD

DOWN

CCESS

CONTROL

BOA

RD.

POWERW

AVE

700

DIP

SWITCH MACHINE

1 MACHINE

(DEFAULT)

OFF

(DEFAULT)

A-13

INSTALLATION

A-13

CONTROL BOARD SETUP FOR SYNCHRONIZED TANDEM

FIGURE A.9

, E

CR S

CC A

F ND

C ES

70 S

AVE

POWER WAVE®S700

A-14

INSTALLATION

A-14

RECOMMENDED WORK CABLE SIZES FOR ARC WELDING

Connect the electrode and work cables between the

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

applications, reverse the

S700

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.

The following recommendations apply to all output polarities and weld modes:

• 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.

POWER WAVE®S700

A-15

INSTALLATION

OUTPUT CABLE GUIDELINES (Table A.1)

A-15

Amperes

200

250

300

350

400

Percent Duty

Cycle

100

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED COPPER - RATED 0 to 50 Ft.

2/0

1/0

2/0

3/0

50 to 100 Ft.

2/0

1/0

2/0

3/0

100 to 150 Ft.

2/0

3/0

167°F (75°C)]**

150 to 200 Ft.

1/0

2/0

3/0

200 to 250 Ft.

1/0

2/0

3/0

4/0

500

600

650

700

800

900

** 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).

100

2/0

3/0

2-1/0

3/0

2-1/0

2-2/0

3-1/0

2-3/0

2-4/0

3-3/0

2/0

3/0

2-1/0

3/0

2-1/0

2-2/0

3-1/0

2-3/0

2-4/0

3-3/0

3/0

2-1/0

4/0

2-1/0

2-3/0

3-1/0

2-3/0

2-4/0

3-3/0

3/0

4/0

2-2/0

2-3/0

2-4/0

3-3/0

4/0

2-3/0

2-4/0

4-2/0

3-3/0

POWER WAVE®S700

A-16

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.10).

A-16

There are several different sense lead configurations that can be used depending on the application. In extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables.

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.

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

Electrode Voltage Sensing

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.

Depending upon the process, inductance within the electrode and work cables can influence the voltage apparent at the studs of the welder and can have a dramatic negative effect on welding performance. To counteract this negative effect, remote voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board. Sense lead kits (K1811-XX) are available for this purpose.

S700 has accurate data about the arc condi-

The remote ELECTRODE sense lead (67) is built into the wire feeder control cable and accessible at the wire drive. It should always be 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 through software.

FIGURE A.10

WORK

POWER WAVE®S700

A-17

INSTALLATION

General Guidelines for Voltage Sense Leads

A-17

If Sense Leads ARE NOT Used:

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)

• 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.

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

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.

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.11)

TABLE A.2

Process

Electrode Voltage Sensing

67 lead

GMAW

GMAW-P

FCAW GTAW

SMAW

(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 enabled).

(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 Voltage sense at studs

FIGURE A.11

DIRECTION OF TRAVEL

(1)

Work Voltage Sensing

21 lead

21 lead optional 21 lead optional

21 lead optional Voltage sense at studs Voltage sense at studs

CONNECT ALL SENSE LEADS AT THE END OF THE WELD.

(2)

(3)

CONNECT ALL WORK LEADS AT THE BEGINNING OF THE WELD.

POWER WAVE®S700

A-18

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.12)

FIGURE A.12

POWER

SOURCE

WER

PO SOURCE

A-18

POWER SOURCE #1

WER

PO SOURCE

POWER

SOURCE

WER

SOURCE

POWER WAVE®S700

A-19

INSTALLATION

A-19

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.

COMMON EQUIPMENT CONNECTIONS

Connection Between Power Source and ArcLink Compatible Wire Feeders

The K1543-xx 5-pin ArcLink heavy duty K2683-xx ArcLink 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 S700 is located on the rear panel.

connection on the Power Wave

/ Power Feed™sys-

control cable or the

control cable connects

and

Note: DeviceNet cables should not be routed with weld cables, wire drive control cables, or any other current carrying device that can create a fluctuating magnetic field.

DeviceNet cables must be sourced locally by the customer. For additional guidelines refer to the “DeviceNet Cable Planning and Installation Manual” (Allen Bradley publication DN-6.7.2).

Connection Between Power Source and Ethernet Networks

The Power Wave

S700 is equipped with a 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.

Connections Between Power Sources in Multi-Arc Applications

The Power Wave

nector such that two power sources can be used for a

S700 is equipped with an I/O con-

Synchronized Tandem application. An Autodrive 19 Tandem controller is required for tandem welding. Refer to Connection Diagrams for more information on the Synchronized Tandem configuration.

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.

Connection Between the Power Source and Optional DeviceNet Programmable Logic Controller (PLC)

It is sometimes more practical and cost effective to use a custom PLC interface to control a system. The

Power Wave

S700 is equipped with a 5-pin DeviceNet mini-style receptacle for this purpose. The receptacle is located on the rear panel of the machine. The DeviceNet cable is keyed and polarized to prevent improper connection.

POWER WAVE®S700

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.

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

S700ʼs duty cycle ratings.

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

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

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 power is applied to the Power Wave®S700 the status lights will flash green for up to 60 seconds. This is normal and indicates the Power Wave forming a self test and mapping (identifying) each component in the local ArcLink system. The status lights will also flash green as a result of a system reset or configuration change during operation. When the status lights become steady green the system is ready for normal operation.

If the status lights do not become steady green consult the troubleshooting section of this manual for further instruction.

S700 is per-

SYNC TANDEM CONNECTOR

WORK SENSE LEAD CONNECTOR

POWER WAVE®S700

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL

B-2

POWER WAVE®S700

B-3

OPERATION

B-3

PRODUCT DESCRIPTION

PRODUCT SUMMARY

The Power Wave inverter and is rated for 700 amps, 44 volts at a 100% duty cycle or 900 amps, 44 volts at a 60% duty cycle. It operates on 380V-415V, 440V-460V, 500V, or 575V 50 Hz or 60 Hz, 3 phase power, so that it can be used worldwide. However, a CE filter kit (K2444-4) is required for CE compliance. Switching between input voltages is made simple by use of a single reconnect panel. The power source is designed with a rugged case that carries an IP23 environmental rating for both indoor and outdoor use. Transporting and lifting the Power Wave and integrated fork-lift tracks in the machine base. A duplex 10A, 115V receptacle is located on the case back for auxiliary power.

The Power Wave with the current range of ArcLink feeders and accessories, such as the Power Feed series wire feeders, via connectivity through a 5-pin circular connector on the case back. Other Lincoln wire feeders and non-Lincoln wire feeders cannot be used. The machine comes equipped with an Ethernet connector useful for software upgrades and access to Power Wave Production Monitoring DeviceNet connector for PLC interfacing. For robotic and tandem systems, the Power Wave patible with Autodrive Controller and Wire Feeders.

Each machine is factory preprogrammed with multiple welding procedures, typically including GMAW, GMAW-P, FCAW, SMAW, CAC, and GTAW for a variety of materials, including mild steel, stainless steel, cored wires, and aluminum. All welding programs and procedures are configured through software for the Power Waves (http://powerwavesoftware.com/). For tandem robotic welding a 6-pin sync connector comes standard on the Power Wave with the proper accessories, this will allow for unlocking of additional tandem weld modes.

S700 is an advanced-process DC

S700 are made simple though a lift bale

S700 is designed to be compatible

software tools like Checkpoint™and

™

. It also comes standard with a

available at

S700. When connected

compatible wire

S700 is com-

RECOMMENDED PROCESSES AND EQUIPMENT

The Power Wave®S700 is recommended for semi-automatic welding, robotic welding, and can be used for tandem welding with additional accessories. The Power Wave

S700 can be set up in a number of configurations, some requiring optional equipment or welding programs.

RECOMMENDED EQUIPMENT

The Power Wave®S700 is designed to be compatible with the current range of Power Feed semi-automatic welding. The Power Wave also designed for robotic applications and can communicate with Fanuc RJ-3 or RJ-3iB controllers via

ArcLink Wave

. For robotic and tandem systems, the Power

S700 is compatible with Autodrive Controller

and Wire Feeders.

wire feeders for

S700 is

RECOMMENDED PROCESSES

The Power Wave®S700 is a multi-process inverter power source capable of regulating current, voltage, and power of the welding arc. The Power Wave

S700 has an output range of 20 to 900 amps, and supports a number of standard processes including synergic GMAW, GMAW-P, FCAW-G, FCAW-S, CAG, SMAW, and GTAW on various materials especially steel, aluminum and stainless.

PROCESS LIMITATIONS

The Power Wave®S700 is suitable only for the processes listed.

Do not use the Power Wave applications.

S700 for pipe thawing

EQUIPMENT LIMITATIONS

Operating temperature range is -20° C to + 40° C (-4°F to 104ºF).

Proper configuration and options allow other equipment such as PLCʼs or computers to interface with a Power Wave

through a DeviceNet, ArcLink, or Ethernet interfaces. In some cases, interface kits may be required for analog control.

POWER WAVE®S700

Only ArcLink compatible wire feeders and accessories

may be used with the Power Wave

S700. Other Lincoln wire feeders and non-Lincoln wire feeders are not compatible with this power source.

The Power Wave

S700 will support a maximum average output of 700A/44V at 100% duty cycle or 900A/44V at a 60% duty cycle.

B-4

Model

K1785-XX

K2709-XX

OPERATION

Basic Package

K3279-1

K2230-1 K1543-xx K1811-xx

K3279-1 K2685-1

K3171-1 K1543-xx K1785-xx K1811-xx

Power Wave® S700 Autodrive 4R220 Wire Drive AutoDrive 19 Tandem Control Cable (5 pin – 5 pin) - power source to Autodrive 19 Tandem Control Cable (14 pin – 14 pin) – Autodrive 19 Tandem to wire drive Sense Lead (work)

ROBOTIC FEEDER CONTROL CABLES AND ADAPTERS

Connectors &

Length

14M – 14F

Power Wave®S700 Power Feed Control Cable (5 pin – 5 pin) - power source to wire feeder Sense Lead (work)

Sync Tandem Package (2 of each Required)

K2444-4

K2683-xx

10M Wire Feeder

Common Optional Kits

CE, C-Tick Filter Kit Heavy Duty ArcLink Control Cable

Robotic Wire Drive Cables (14-pin)

Collar

Both ends

On male end only

Description for 3rd Generation Power Waves

• Connects from i400, R350, R500 or AutoDrive 19 to PF10R version K1780-2 and later or to robot base.

•High Flex for Robots (ACE)

Same as past K680/K681 series.

•Connects AutoDrive Feeder pigtail directly to i400, R350, R500 or AutoDrive 19 controller.

•Externally mounted wire feeder cable for use with robot arms not equipped with an integral cable.

B-4

Model

K1805-1

K1785-2

Cable, Controller, and Power Source Adapters

Connectors &

Length

14M – 22F

(18”)

14M – 14F

(18”)

K1543-XX

K2683-XX

Collar

On male end

• Adapter for i400, R350, R500 or AutoDrive 19 to

only Both ends

•Connects integral robot arm cable to PF10R version

ArcLink Cables (5-pin)

Model

Connectors &

Length

5M – 5F

POWER WAVE®S700

Description for 3rd Generation Power Waves

allow use of K1795 cable.

K1780-2 and later.

Collar

On male end only

Brass collar on male end only

B-5

OPERATION

DESIGN FEATURES

• Designed for High Amprage, High Duty Cycle Applications.

• Severe Duty Design for outdoor use (IP23 rating).

• iARC™ Digital Control – 90 times faster than the previous generation, delivering a responsive arc.

• Fork lift access base design for ease of installation or movement.

• Output range: 20 – 900 Amps.

• Coaxial Transformer Technology – gives reliable high-speed operation.

• Passive Power Factor Correction – reliably gives 95% power factor for lower installation costs.

• 88% Efficiency rating – reduces electrical utility costs.

• Seamless integration with Ethernet, DeviceNet and ArcLink.

• Circuit breaker protected 10-amp, 115V auxiliary power.

• F.A.N. (fan as needed). Cooling fan runs when the output is energized, and for 5 minutes after arc is extinguished.

• Thermal protection by thermostats with Thermal Indicator LED.

• Built-in Line Voltage Compensation holds the output constant over ±10% input voltage fluctuations.

• Electronic over current protection.

• Input over voltage protection.

• Utilizes digital signal processing and microprocessor control.

• Simple, reliable input voltage changeover.

• Conforms to the IEC 60974-1 and GB15579-1995 Standards.

• Ethernet connectivity via RJ-45 connector.

• Potted PC boards for enhanced ruggedness/reliability.

• ArcLink®, Ethernet and DeviceNet™ Communication – Offers remote process monitoring, control and troubleshooting.

• True Energy™ - Measures, calculates and displays instantaneous energy in the weld for critical heat input calculations.

• Production Monitoring™ 2.2 – Track equipment usage, store weld data, and configure limits to assist in welding efficiency analysis.

• Check Point™ – is the newest data collection and reporting technology available for the latest models of the Lincoln Electric Power Wave Welding Power Sources.

family of

B-5

POWER WAVE®S700

B-6

OPERATION

CASE FRONT CONTROLS

(See Figure B.1)

1. POWER SWITCH: Controls input power to the Power Wave

2. STATUS LED - A two color light that indicates the condition of the system. Normal

operation is a steady green light. Error conditions are detailed in the Trouble Shooting Section of this manual. A red light indicates an error.

NOTE: The Power Wave® S700ʼs status light will flash green for up to 60 seconds when the machine is first turned on. This is a normal situation as the machine goes through a self test at power up.

3. THERMAL LED - A yellow light that comes on when an over-temperature condition

occurs. Output is disabled until the machine cools down. When cool, the light goes out and output is re-enabled.

4. ACCESS PANEL - This panel provides access to the control board compartment.

5. POSITIVE OUTPUT STUDS

S700.

B-6

6. NEGATIVE OUTPUT STUDS

7. METER - Optional kit used to display arc current and voltage while welding in any

mode.

FIGURE B.1

(Optional)

POWER WAVE®S700

B-7

OPERATION

CASE BACK CONTROLS

(See Figure B.2)

1. 115V/10A AUXILIARY OUTPUT RECEPTACLE.

2. 10 AMP CIRCUIT BREAKER (CB1) - Protects the 40VDC wire feeder power supply.

3. 10 AMP CIRCUIT BREAKER (CB2) - Protects the 115VAC auxiliary power receptacle.

4. ETHERNET CONNECTOR (RJ-45) - Provides Ethernet communication to remote equipment.

5. WORK SENSE LEAD CONNECTOR (4-PIN) - Connection point for the 21 and 67 leads.

6. SYNC-TANDEM CONNECTOR - Used to interconnect machines for tandem robotic welding processes.

7. ARCLINK (5-PIN) - Provides power and communication to the controller.

8. DEVICENET CONNECTOR - Provides DeviceNet communication to remote equipment.

B-7

FIGURE B.2

POWER WAVE®S700

B-8

OPERATION

B-8

COMMON WELDING PROCEDURES

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 builder/user is and must be solely responsible for welding program selection.

The steps for operating the Power Wave vary depending upon the user interface of the welding system. The flexibility of the Power Wave the user customize operation for the best performance.

Find the program in the welding software that best matches the desired welding process. The standard software shipped with the Power Waves S700 encompasses a wide range of common processes and will meet most needs. If a special welding program is desired, contact the local Lincoln Electric sales representative.

To make a weld, the Power Wave

know the desired welding parameters. Waveform Control Technology™ allows full customization of Strike, Run-in, Crater and other weld parameters for exacting performance.

DEFINITION OF WELDING MODES

S700 will

S700 lets

S700 needs to

BASIC WELDING CONTROLS

Weld Mode

Selecting a weld mode determines the output characteristics of the Power Wave 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

S700 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

S700 then uses the WFS setting to adjust the voltage and current according to settings contained in the machine.

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.

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.

S700 power source.

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.

POWER WAVE®S700

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.

B-9

OPERATION

B-9

SMAW (STICK) WELDING

The welding current and Arc Force settings can be set

™

through a Power Feed

10M or Power Feed™25M

wire feeder.

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

10M or Power Feed® 25M wire feeder.

Feed

The Power Wave

S700 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 S700 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 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. Using a preset voltage becomes impractical and instead the arc length is set by adjusting “trim”.

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®S700

B-10

OPERATION

Most pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave

S700 will automatically recalculate the waveform parameters to maintain similar arc properties.

The Power Wave

S700 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

S700 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-10

WELD PROCESS ADJUSTMENTS

Depending on the weld mode, there are a number of adjustments that can be made, including but not limited to Current, Voltage and WFS. These adjustments control the basic parameters of the weld.

UltimArc™ Control -10.0

FIGURE B.4

UltimArc™ Control OFF

POWER WAVE®S700

UltimArc™ Control +10.0

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

CE/C-Tick Filter Kit

Filter mounts inside the power source to meet EMC requirements of Europe and Australia.

Order K2444-4

User Interface / Meter Kit

Mounts on the Control Board Access Panel on the front of the Power Wave® S700. Also displays actual voltage and current while welding in any mode.

Order K3362-1

Work Voltage Sense Lead Kit

Required to accurately monitor voltage at the arc.

Order K940-25 for 25 ft (7.6 m) Order K1811-50 for 50 ft (15.2 m) Order K1811-100 for 100 ft (30.4 m)

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

, Argon, or Argon-blend gas cylin-

POWER WAVE®S700

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.

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

VISUAL INSPECTION

Clean the interior of the machine with a low pressure air stream. Make a thorough inspection of all components. Look for signs of overheating, broken leads or other obvious problems. Many problems can be uncovered with a good visual inspection.

D-1

PERIODIC MAINTENANCE

Calibration of the Power Wave®S700 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, using calibrated meters in test modes.

Thermal Protection

Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will prevent disable output. The thermal LED will remain illuminated during this time. Thermostats are self-resetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fan is operating normally, the power switch may be left on and the reset should occur within a 15 minute period.

ROUTINE MAINTENANCE

Approximately every 6 months the machine should be cleaned with a low pressure air stream. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean these areas:

• All printed circuit boards

• Power switch

• Main transformer

• Input rectifier

• Heatsink fins

• Auxiliary Transformers

• Reconnect Switch Area

• Fan (Blow air through the rear louvers)

Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to insure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to insure case strength and electrical ground continuity.

CALIBRATION SPECIFICATION

Output voltage and current are calibrated at the factory. Generally speaking 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 Power

Wave

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 (http://www.power-

wavesoftware.com/).

Manager Diagnostics Utility to make the

POWER WAVE®S700

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®S700

E-2

TROUBLESHOOTING

USING THE STATUS LED TO TROUBLESHOOT SYSTEM PROBLEMS

The Power Wave®S700 is equipped with a status light. If a problem occurs it is important to note the condition of the status light. Therefore, prior to cycling power to the sys-

tem, check the power source status light for error sequences as noted below.

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

TABLE E.1

Light

Condition

Main control board status light and Input control board

E-2

Troubleshooting the Power Wave

The STATUS LIGHT is a two color light that indicates system errors. Normal operation is a steady green light. Error conditions are indicated in the following chart.

Meaning

Using the Status LED

Steady Green

Blinking Green

Alternating Green and Red

Steady Red

Blinking Red

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

ment connected to its ArcLink

Occurs during power up or a system reset and indicates the Power Wave

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

figuration is changed during operation.

Non-recoverable system fault. If the Status light is 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.

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

Not applicable.

network.

S700 is mapping (identifying)

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®S700

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

ERROR CODES FOR THE POWER WAVE®S700

The following is a list of possible error codes that the Power Wave®S700 can output via the status light (see “Troubleshooting the Power Wave

System Using the Status LED”).

MAIN CONTROL BOARD ( “STATUS” LIGHT)

Error Code #

Indication

31 Primary overcurrent error.

32 Capacitor “A” under voltage

(Left side facing machine)

33 Capacitor “B” under voltage

(Right side facing machine)

34 Capacitor “A” over voltage

(Left side facing machine)

35 Capacitor “B” over voltage

(Right side facing machine)

36 Thermal error

37 Softstart error

41 Secondary overcurrent error

Excessive primary current present. May be related to a switch board or output rectifier failure.

Low voltage on the main capacitors. May be caused by improper input configuration or an open/short circuit in the primary side of the machine.

Excess voltage on the main capacitors. May be caused by improper input configuration, excessive line voltage, or improper capacitor balance (see Error 43).

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

Capacitor precharge failed. Usually accompanied by codes 32-35.

The secondary (weld) current limit has been exceeded. When this occurs the machine output will phase back to 100 amps, typically resulting in a condition referred to as “noodle welding”.

43 Capacitor delta error

49 Single phase error

Other

The maximum voltage difference between the main capacitors has been exceeded. May be accompanied by errors 32-35. May be caused by an open or short in the primary or secondary circuit(s).

Indicates machine is running on single phase input power. Usually caused by the loss of the middle leg (L2).

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®S700

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

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

Input fuses keep blowing, or input breaker keeps tripping.

TROUBLESHOOTING

POSSIBLE

CAUSE

Basic Machine Problems

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

1. Make certain that fuses or breakers are properly sized.

2. Welding procedure is drawing too much output current, or duty cycle is too high.

3. There is internal damage to the power source.

1. See Installation section of this

2. Reduce output current, duty

3. Contact an authorized Lincoln

RECOMMENDED

COURSE OF ACTION

manual for recommended fuse and breaker sizes.

cycle, or both.

Electric Service facility.

E-4

Machine will not power up (no lights, no fan, etc.)

Thermal LED is lit.

Machine won't weld, canʼt get any output. (CR1 will not pull in.)

1. Make certain that the Power Switch (SW1) is in the “ON" position.

2. Fuse F1 (in reconnect area) may have opened.

3. Input voltage selection made improperly.

4. Circuit breaker CB1 (on case back) may have opened.

1. Output rectifier thermostat has opened. After machine has cooled, reduce load, duty cycle, or both.

2. DC Bus PC board thermostat has opened.

1. Input voltage is too low or too high.

2. If the Thermal LED is also lit.

3. Primary current limit has been exceeded. Possible short in output circuit. Turn machine off. Remove all loads from the output of the machine. Turn back on.

4. This problem will normally be accompanied by an error code. Error codes are displayed as a series of red and green flashes by the status light.

1. Check

2. Replace. Also, check input voltage selection.

3. Power down, check input voltage reconnect according to diagram on reconnect cover.

4. Reset.

1. Check for material blocking intake or exhaust louvers.

2. Check for excessive load on 40VDC supply.

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

2. See “Yellow Thermal LED is Lit" section.

3. If condition persists, turn power off, and contact an authorized Lincoln Electric Field Service facility.

4. See “Troubleshooting the Power Wave / Power Feed System Using the Status LED” section of this text.

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®S700

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

Thermal LED is ON

Machine wonʼt produce full output.

Auxiliary receptacle is dead -- no auxiliary voltage.

The Power Wave is triggered to weld, but there is no output.

Improper fan operation

Basic Machine Problems (Continued)

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

2. Input may be single phased.

3. Secondary current or voltage may not be properly calibrated.

1. Circuit breaker CB2 (on case back) may have opened.

2. Fuse F1 (in reconnect area) may have opened.

1. Fuse F1 (in reconnect area) may have opened.

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

2. Make certain the input voltage is proper on all three input lines.

3. Check calibration.

1. Reset.

2. Replace.

1. Replace.

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®S700

F-1

DIAGRAMS

F-1

POWER WAVE®S700

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.02

12.59

36.68

35.71

CENTER OF

GRAFITY

27.02

30.10

18.48

L16371

19.12

18.48

CENTER OF

GRAVITY

12.59

POWER WAVE®S700

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vêtements

mouillés entrer en contact avec des pièces sous tension.

 Isolez-vous du travail et de la terre.  Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

 Isolieren Sie sich von den Elektroden

und dem Erdboden!

 Não toque partes elétricas e electro-

dos com a pele ou roupa molhada.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

 Keep your head out of fumes.  Use ventilation or exhaust to remove

fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

 Gardez la tête à l’écart des fumées.  Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.  Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de alimentación

de poder de la máquina antes de iniciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten abschal-

ten! (Netzstrom völlig öffnen; Maschine anhalten!)

 Não opere com as tampas removidas.  Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

 Anlage nie ohne Schutzgehäuse oder

Innenschutzverkleidung in Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos ou

guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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.

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.

Lincoln Electric IM10144 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual