Lincoln Electric POWER WAVE R500 Operator's Manual
Operator’s Manual
POWER WAVE
®
R500
For use with machines having Code Numbers:
12483
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Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10295 | Issue D ate June-15
© Lincoln Global, Inc. All Rights Reserved.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
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no later than the following business day.
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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.
se corrective lenses if necessary
U
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you 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.
Safety 01 of 04 - 06/15/2016
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
heir removal is complete. Always use the greatest care when
t
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 02 of 04 - 06/15/2016
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
f physical contact with work and ground.
o
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 hardfacing
(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 06/15/2016
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
rom starting a fire. Remember that welding sparks and hot
f
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,
tc. should be suitable for the application and
e
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected
to physical damage.
• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
POWERED EQUIPMENT.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
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.
Safety 04 of 04 - 06/15/2016
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
________________________________________________________________________________ ................
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 List................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
_______________________________________________________________________________
6
TECHNICAL SPECIFICATIONS - POWER WAVE®R500
POWER SOURCE-INPUT VOLTAGE AND CURRENT
Model
Duty Cycle
40% rating
K3169-2
100% rating
INPUT
VOLTAGE/PHASE/
FREQUENCY
380-415/3/50/60
460/3/50/60
575/3/50/60
nput Voltage ± 10%
I
00*/460/575
4
nput Amperes
I
1/37/29
4
50/60 Hz
(*includes 380V to 415V)
30/27/21
RATED OUTPUT
GMAW
40%
550 Amps
41.5 Volts
60%
500 Amps
39 Volts
100%
450 Amps
36.5 Volts
40%
550 Amps
42 Volts
SMAW
60% 100%
500 Amps
40 Volts
450 Amps
38 Volts
RECOMMENDED INPUT WIRE AND FUSE SIZES
Idle Power
500 Watts Max.
(fan on)
GTAW-DC
40%
550 Amps
32 Volts
1
INSTALLATIONPOWER WAVE®R500
ower Factor @
P
Rated Output
60%
500 Amps
30 Volts
.95
100%
450 Amps
28 Volts
INPUT
VOLTAGE / PHASE/
FREQUENCY
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 tripping 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
41A, 40%
37A, 40%
29A, 40%
CORD SIZE
AWG SIZES
(mm2)
8 (10)
8 (10)
10 (7)
3
TIME DELAY FUSE
OR BREAKER
2
AMPERAGE
60
45
35
A-1
MODEL
ROCESS
P
GMAW
GMAW-Pulse
FCAW
GTAW-DC
SMAW
HEIGHT
WELDING PROCESS
OUTPUT RANGE (AMPERES)
40-550A
5-550A
55-550A
PHYSICAL DIMENSIONS
WIDTH
OCV (Uo)
Mean Peak
70V 73V
24V 36V
60V 63V
DEPTH
INSTALLATIONPOWER WAVE®R500
WEIGHT
K3169-2
OPERATING TEMPERATURE RANGE
Environmentally Hardened: -4°F to 104°F (-20°C to 40°C)
IP23 155º(F) Insulation Class
22.45 in ( 570 mm)
* Weight does not include input cord.
14.00in ( 356 mm)
TEMPERATURE RANGES
STORAGE TEMPERATURE RANGE
Environmentally Hardened: -40°F to 185°F (-40°C to 85°C)
24.80in ( 630mm)
150 lbs (68 kg)
*
A-2
INSTALLATIONPOWER WAVE®R500
SAFETY PRECAUTIONS Read this entire
nstallation section before you start installation.
i
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should
perform this installation.
• Turn the input power OFF at the
disconnect switch o r 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.
• 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.
LIFTING
Both handles should be used when lifting POWER WAVE® R500.
hen using a crane or overhead device a lifting strap should be
W
connected to both handles. Do not attempt to lift the
POWER WAVE® R500 with accessories attached to it.
STACKING
he POWER WAVE® R500 cannot be stacked.
T
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.
INPUT AND GROUND CONNECTIONS
Only a qualified electrician should connect the POWER WAVE®
R500. Installation should be made in accordance with the
appropriate National Electrical Code, all local codes and the
information in this manual.
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.
-------------------------------------------------------------
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.
• Do not mount the POWER WAVE® R500 over combustible
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.
This equipment is for industrial use only and it is not intended for
use in residential locations where the electrical power is provided by
the public low-voltage supply system. There can be potential difficulties in residential locations due to conducted as well as radiated
radio-frequency disturbances. The EMC or RF classification of this
equipment is Class A.
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® R500 may
adversely affect the operation of RF controlled equipment, which
may result in bodily injury or damage to the equipment.
A-3
WARNING
POWER CONNECTION BLOCK
INPUT CORD ST RAIN RELIEF
CONNECT EACH PHASE OF A THREE-PHASE
CONDUCTOR HERE
GROUND CONNECTION
CONNECT GROUND LEAD PER LOCAL
AND NATIONAL ELECTRIC CODE
ROUTE INPUT CORD
THROUGH RELIEF AND
TWIST NUT TO TIGHTEN
INPUT POWER
ACCESS DOOR
Only a qualified electrician should
connect the input le a d s t o the
POWER WAVE®R500. Connections
should be made in accordance with
all local and national electrical
codes and the connecti o n 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 GROUNDING LUG
(LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY
(EARTH) GROUND.
INSTALLATIONPOWER WAVE®R500
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®R500 ON/OFF
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.
FIGURE A.1
-------------------------------------------------------------
A-4
GMAW (MIG) WELDING
RREEGGUULLAATTOORR
FFLLOOWW MMEETTEERR
GGASAS HHOOSSEE
WWOORRKK PPIIEECCEE
WWOORRKK CCLLAAMMPP
TTOO PPOOSSIITTIIVEVE ((++)) SSTTUUDD
TTOO NNEEGGAATTIIVEVE ((--)) SSTTUUDD
PPFF1010--MM
WWIIRREE F FEEEEDDEERR
A
ARCRCLLIINNKK CCAABBLLEE
KK11554433--[[XXXX]]
MIG PROCESS
An arclink compatible wire feeder is recommended for Mig welding. Refer to Figure A.3 for the connection details.
FIGURE A.3
INSTALLATIONPOWER WAVE®R500
A-5
RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING
onnect the electrode and work cables between the appropriate
C
output studs of the
lines:
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
per the following guide-
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 INFORMA-
TION” located in the front of this Instruction Manual.
INSTALLATIONPOWER WAVE®R500
eneral Guidelines
G
• Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive voltage
drops caused by undersized welding cables and poor connections often result in unsatisfactory welding performance.
lways use the largest welding cables (electrode and work)
A
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 167°F (75°C)]**
0 to 50 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
50 to 100 Ft.
2
1
2/0
2/0
3/0
3/0
2/0
2/0
100 to 150 Ft.
2
1
2/0
3/0
3/0
4/0
3/0
3/0
150 to 200 Ft.
1
1
2/0
3/0
3/0
4/0
3/0
3/0
200 to 250 Ft.
1/0
1/0
3/0
4/0
4/0
2-3/0
4/0
4/0
A-6
B
A
C
WORK
POWER
WAVE
R500
INSTALLATIONPOWER WAVE®R500
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 over-
ll inductance of the cabling system including cable size, and
a
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
age sense leads are used to improve the accuracy of the arc volt-
ge information supplied to the control pc board. Sense Lead Kits
a
(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
re no requirements for setting-up the machine to use remote
a
sense leads. This feature can be disabled through the Weld
Man a g er Uti l i ty (av a i lable 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 m i s sing or imp r o perly 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 Sensing Overview
Voltage sense leads requirements are based on the weld process
(See Table A.2)
The best arc performance occurs when the POWER WAVE®R500
has accurate data about the arc conditions.
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 volt-
TABLE A.2
Process
Electrode Voltage Sensing
67 lead
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 (K1543-xx).
(2)
When a work voltage sense lead (21) is connected the power source will automatically switch over to using this feedback (if the auto sense feature is enable).
(3)
Negative polarity semi-automatic process operation WITHOUT use of a remote work sense lead (21) requires the Negative Electrode Polarity attribute to be set.
67 lead required
67 lead required
67 lead required
Voltage sense at studs
(1)
Work Voltage Sensing
21 lead
21 lead optional
21 lead optional
21 lead optional
Voltage sense at studs
(2)
(3)
(3)
(3)
FIGURE A.5
A-7
Electrode Voltage Sensing
The remote ELECTRODE sense lead (67) is built into the 5-pin
rclink control cable and is always connected to the wire drive
a
feed plate when a wire feeder is present. Enabling or disabling
lectrode voltage sensing is application specific, and automati-
e
cally configured by the active weld mode.
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 fourpin 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."
INSTALLATIONPOWER WAVE®R500
Negative Electrode Polarity
The POWER WAVE®R500 has the ability to automatically sense
the polarity of the sense leads. With this feature there are no
set-up requirements for welding with negative electrode polarity.
This feature can be disabled through the Weld Manager Utility
(available at www.powerwavesoftware.com) or through the set
up menu (if a user interface is installed into the power source).
A-8
DIRECTION
O F TRA VEL
CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.
CONNECT ALL SEN SE
LEADS AT THE END
OF THE WELD.
INSTALLATIONPOWER WAVE®R500
VOLTAGE SENSING
CONSIDERATIONS FOR MULTIPLE
ARC SYSTEMS
Special care must be taken when more than one arc is welding
imultaneously on a single part. Multiple arc applications do not
s
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
If Sense Leads ARE Used:
• Position the sense leads out of the path of the weld current.
specially any current paths common to adjacent arcs.
E
Current from adjacent arcs can induce voltage into each oth-
rs current paths that can be misinterpreted by the power
e
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)
A-9
INSTALLATIONPOWER WAVE®R500
P
O
W
ER
SOURCE
#2
POWER
SOURCE
#1
POWER
PO
WER
SOURCE
SOURCE
#1
PO
WER
SOURCE
#2
#2
P
OWER
SOURCE
#1
• 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)
IGURE A.7
F
A-10
INSTALLATIONPOWER WAVE®R500
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®/ Power Feed™systems. 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®and Ethernet connections.
Product specific Installation Instructions
Connection Between Power Source and Ethernet
Networks
he POWER WAVE
T
®
500 is equipped with an IP67 rated ODVA
R
compliant RJ-45 Ethernet connector, which is located on the rear
anel. All external Ethernet equipment (cables, switches, etc.),
p
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.
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 p revent improper connection. Best resul ts 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).
®
A-11
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