Lincoln Electric POWER WAVE S500 Service Manual
Lincoln Electric Power Wave S500 is a high-performance welding machine designed for professional welders. It offers precise control over the welding process, allowing you to achieve high-quality welds on a wide range of materials, including steel, stainless steel, and aluminum. With its advanced features and user-friendly interface, the Power Wave S500 is an ideal choice for demanding welding applications in industries such as construction, fabrication, and repair.
Advertisement
Advertisement
POWER WAVE
®
S500
For use with machines having Code Numbers:
11813
SERVICE MANUAL
Need Help? Call 1.888.935.3877 to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you no later than the following business day.
For Service outside the USA:
Email: [email protected]
SVM239-A
| Issue D ate 13-Oct
© Lincoln Global, Inc. All Rights Reserved.
i SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
i
ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
ELECTRIC AND
MAGNETIC FIELDS may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete.
Always use the greatest care when working near moving parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.
2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding.
2.c. Exposure to EMF fields in welding may have other health effects which are now not known.
2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
___________________________________________________
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.
2.d.5. Do not work next to welding power source.
POWER WAVE ® S500
ii 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.
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.
ii
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
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.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas and other irritating products.
5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer ʼ s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer ʼ s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
POWER WAVE ® S500
iii
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.
SAFETY
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.
iii
7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.
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.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to physical damage.
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.
• 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.
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).
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.
6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.
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.
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.
FOR ELECTRICALLY powered equipment.
8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.
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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer ʼ s recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer ʼ 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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
POWER WAVE ® S500
iv SAFETY
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: iv
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d ʼ incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d ʼ incendie.
Sûreté Pour Soudage A L ʼ Arc
1. Protegez-vous contre la secousse électrique:
8. S ʼ assurer que la masse est connectée le plus prés possible de la zone de travail qu ʼ il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d ʼ autres endroits
éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d ʼ incendie ou d ʼ echauffement des chaines et des câbles jusqu ʼ à ce qu ʼ ils se rompent.
a. Les circuits à l ʼ électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s ʼ isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.
d. Ne jamais plonger le porte-électrode dans l ʼ eau pour le refroidir.
e. Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s ʼ applicuent aussi au pistolet de soudage.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d ʼ opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l ʼ arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n ʼ importe quelle partie du corps.
3. Un coup d ʼ arc peut être plus sévère qu ʼ un coup de soliel, donc:
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié ainsi qu ʼ un verre blanc afin de se protéger les yeux du rayonnement de l ʼ arc et des projections quand on soude ou quand on regarde l ʼ arc.
b. Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l ʻ arc.
c. Protéger l ʼ autre personnel travaillant à proximité au soudage à l ʼ aide d ʼ écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l ʼ arc de soudage. Se protéger avec des vêtements de protection libres de l ʼ huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l ʼ on pique le laitier.
1. Relier à la terre le chassis du poste conformement au code de l ʼ électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, I ʼ installation et l ʼ entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l ʼ interieur de poste, la debrancher à l ʼ interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
POWER WAVE ® S500
v SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer ʼ s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g., guarding of industrial equipment; e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; h) the time of day that welding or other activities are to be carried out.
POWER WAVE ® S500 v
vi SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer ʼ s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer ʼ s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer ʼ s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.” vi
POWER WAVE ® S500
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
RETURN TO MAIN INDEX
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
I
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-690
POWER WAVE ® S500
A-1 TABLE OF CONTENTS - INSTALLATION SECTION A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2/A-3
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Input And Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
High Frequency Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Input Fuse And Supply Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Input Voltage Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6/A-8
Recommended Work Cable Sizes For Arc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
General Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
Cable Inductance And Its Effects On Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10
Remote Sense Lead Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-10/A-11
Voltage Sensing Considerations For Multiple Arc Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-12/A-13
Control Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-14
POWER WAVE ® S500
A-2 INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE
®
S500
A-2
MODEL DUTY
CYCLE
POWER SOURCE-INPUT VOLTAGE AND CURRENT
INPUT VOLTAGE ± 10% INPUT AMPERES IDLE POWER POWER FACTOR
@ RATED OUTPUT
K2904-1 40% rating
100% rating
208/230/400*460/575
50/60 Hz
(includes 380V to 413V)
80/73/41/37/29 500 Watts Max.
(fan on)
60/54/30/27/21
.95
RATED OUTPUT
INPUT
VOLTAGE/PHASE/
FREQUENCY
40%
200-208/3/50/60 550 Amps
41.5 Volts
230/3/50/60
380-415/3/50/60
460/3/50/60
GMAW
60% 100% 40%
500 Amps
39 Volts
450 Amps
36.5 Volts
550 Amps
42 Volts
SMAW
60% 100%
500 Amps
40 Volts
450 Amps
38 Volts
40%
550 Amps
32 Volts
GTAW-DC
60%
500 Amps
30 Volts
100%
450 Amps
28 Volts
575/3/50/60
RECOMMENDED INPUT WIRE AND FUSE SIZES
1
INPUT VOLTAGE/PHASE/
FREQUENCY
MAXIMUM INPUT AMPERE
RATING AND DUTY CYCLE
CORD SIZE 3 AWG
SIZES (mm 2 )
TIME DELAY FUSE OR
BREAKER 2 AMPERAGE
200-208/3/50/60 80A, 40% 2 (35) 100
230/3/50/60
380-415/3/50/60
460/3/50/60
575/3/50/60
73A, 40%
41A, 40%
37A, 40%
29A, 40%
2 (35)
6 (13)
6 (13)
8 (10)
90
60
45
35
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.
POWER WAVE ® S500
A-3 INSTALLATION A-3
PROCESS
WELDING PROCESS
OUTPUT RANGE (AMPERES) OCV (Uo)
GMAW
GMAW-Pulse
FCAW
GTAW-DC
SMAW
MODEL
K2904-1
HEIGHT
40-550A
5-550A
15-550A
PHYSICAL DIMENSIONS
WIDTH
Mean
60V
24V
60V
DEPTH
22.45 in. (570 mm) 14.00 in. (356 mm) 24.08 in. (630 mm)
Peak
100V
WEIGHT
150 lbs (68kg)*
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE
Environmentally Hardened: -4º to 104ºF (-20º to 40ºC) Environmentally Hardened: -40º to 185ºF (-40º to 85ºC)
IP23 155º(F) Insulation Class
* Weight does not include input cord.
Thermal tests have been performed at ambient temperature. The duty cycle (duty factor) at 40°C has been determined by simulation.
POWER WAVE ® S500
A-4 INSTALLATION
SAFETY PRECAUTIONS
Read this entire installation section before you start installation.
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 ® S500 grounding lug to a proper safety (Earth) ground.
------------------------------------------------------------------------
SELECT SUITABLE LOCATION
WARNING
A-4
FALLING EQUIPMENT can cause injury.
• Lift only with equipment of adequate lifting capacity.
• Be sure machine is stable when lifting.
• Do not operate machine while suspended when lifting.
------------------------------------------------------------------------
STACKING
The Power Wave ® S500 cannot be stacked.
TILTING
Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed.
INPUT AND GROUND CONNEC-
TIONS
Only a qualified electrician should connect the Power
Wave ® S500. Installation should be made in accordance with the appropriate National Electrical Code, all local codes and the information in this manual.
MACHINE GROUNDING
The Power Wave ® S500 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 circulation of clean air.
• Dirt and dust that can be drawn into the machine should be kept to a minimum. The use of air filters on the air intake is not recommended because normal air flow may be restricted. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.
• Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.
• Do not mount the Power Wave ® S500 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.
LIFTING
The frame of the welder must be grounded. A ground terminal marked with a ground symbol is located next to the input power connection block.
See your local and national electrical codes for proper grounding methods.
HIGH FREQUENCY PROTECTION
Locate the Power Wave ® S500 away from radio controlled machinery. The normal operation of the Power
Wave ® S500 may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment.
Both handles should be used when lifting Power
Wave ® S500. When using a crane or overhead device a lifting strap should be connected to both handles. Do not attempt to lift the Power Wave ® S500 with accessories attached to it.
POWER WAVE ® S500
A-5
------------------------------------------------------------------------
(See Figure A.1)
WARNING
INPUT CONNECTION
INSTALLATION
INPUT FUSE AND SUPPLY WIRE
CONSIDERATIONS
Only a qualified electrician should connect the input leads to the Power Wave ® S500. Connections should be made in accordance with all local and national electrical codes and the connection diagrams. Failure to do so may result in bodily injury or death.
A-5
See Technical Specifications 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
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.
The Power Wave ® S500 automatically adjusts to work with different input voltages. No reconnect switch settings are required.
WARNING
ALWAYS CONNECT THE POWER WAVE GROUND-
ING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO
A PROPER SAFETY (EARTH) GROUND.
The Power Wave ® S500 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 ® S500. 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
INPUT CORD STRAIN RELIEF
ROUTE INPUT CORD
THROUGH RELIEF AND
TWIST NUT TO TIGHTEN
GROUND CONNECTION
CONNECT GROUND LEAD PER LOCAL
AND NATIONAL ELECTRIC CODE
POWER CONNECTION BLOCK
CONNECT EACH PHASE OF A THREE-PHASE
CONDUCTOR HERE
POWER WAVE ® S500
INPUT POWER
ACCESS DOOR
A-6
REGULATOR
FLOWMETER
INSTALLATION
CONNECTION DIAGRAMS
GTAW (TIG) WELDING
A user interface is required for adjusting the TIG welding settings. S-series user interface (K3001-2) can be installed into the power source (Figure A.2). Refer to the connection diagrams based on the user interface that is being used. Alternate configurations are possible depending on the wire feeder that is being used.
Refer to the wire feeder ʼ s manual for alternative configurations.
FIGURE A.2
TIG WITH S-SERIES USER INTERFACE
A-6
K30 01-2
SOLENOID K IT
NCLUD ES W
APTER, A REGULATOR)
POWER WAVE ® S500
A-7 INSTALLATION
SMAW (STICK) WELDING
Similar to TIG welding a user interface is required for adjusting the Stick welding settings. A Power Feed wire feeder can be used as the user interface or a
K3001-2 (user interface control panel) can be installed into the power source (Figure A.3). The connection diagram shown is based on the S-Series user interface
(K3001-2). In this diagram the remote control box is optional.
FIGURE A.3
STICK WITH S-SERIES USER INTERFACE
A-7
USER INTERFACE
CONTROL PANEL
K3001-2
TO REMOTE CONTROL
RECEPTACLE
REMOTE CONTROL BOX
K857
TO NEGATIVE (-) STUD
TO POSITIVE (+) STUD
ELECTRODE HOLDER KIT
K2394-1 KIT
(INICLUDES GROUND CLAMP)
WORK CLAMP
WORK PIECE
POWER WAVE ® S500
A-8
REGULATOR
FLOWMETER
INSTALLATION
GMAW (MIG) WELDING
An arclink compatible wire feeder is recommended for
Mig welding. See Figure A.4 for the connection details.
FIGURE A4
MIG PROCESS
A-8
K1543-[XX]
WIRE F EEDER
POWER WAVE ® S500
A-9 INSTALLATION
RECOMMENDED WORK CABLE
SIZES FOR ARC WELDING
GENERAL GUIDELINES
Connect the electrode and work cables between the appropriate output studs of the Power Wave ® S500 per the following guidelines:
• Most welding applications run with the electrode being positive (+). For those applications, connect the electrode cable between the wire drive feed plate and the positive (+) output stud on the power source.
Connect a work lead from the negative (-) power source output stud to the work piece.
A-9
• 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. 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.
• 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).
• 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 .
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.
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.
------------------------------------------------------------------------
For additional Safety information regarding the electrode and work cable set-up, See the standard Safety
Information located in the front of this Service
Manual.
Amperes
Percent Duty
Cycle
TABLE A.1 – OUTPUT CABLE GUIDELINES
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)] **
0 to 50 Ft.
50 to 100 Ft.
100 to 150 Ft.
150 to 200 Ft.
200 to 250 Ft.
200 100 2 2 2 1 1/0
250 100 1 1 1 1 1/0
300 100 2/0 2/0 2/0 2/0 3/0
350 100 2/0 2/0 3/0 3/0 4/0
400 100 3/0 3/0 3/0 3/0 4/0
450 100 3/0 3/0 4/0 4/0 2-3/0
500 60 2/0 2/0 3/0 3/0 4/0
550 40 2/0 2/0 3/0 3/0 4/0
** 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).
POWER WAVE ® S500
A-10 INSTALLATION
CABLE INDUCTANCE AND ITS
EFFECTS ON WELDING
A-10
REMOTE SENSE LEAD SPECIFICA-
TIONS
Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size and loop area. The loop area is defined by the separation distance between the electrode and work cables and the overall welding loop length. The welding loop length is defined as the total of length of the electrode cable (A) + work cable (B) + work path (C) (See Figure A.5).
To minimize inductance always use the appropriate size cables and whenever possible, run the electrode and work cables in close proximity to one another to minimize the loop area. Since the most significant factor in cable inductance is the welding loop length, avoid excessive lengths and do not coil excess cable. For long work piece lengths, a sliding ground should be considered to keep the total welding loop length as short as possible.
VOLTAGE SENSING OVERVIEW
The best arc performance occurs when the Power
Wave ® S500 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 voltage sense leads are used to improve the accuracy of the arc voltage information supplied to the control pc board.
Sense Lead Kits (K940-xx) are available for this purpose.
The Power Wave ® S500 has the ability to automatically sense when remote sense leads are connected.
With this feature there are no requirements for settingup the machine to use remote sense leads. This feature can be disabled through the Weld Manager Utility
(available at www.powerwavesoftware.com
) or through the set up menu (if a user interface is installed into the power source).
CAUTION
Process
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.
------------------------------------------------------------------------
TABLE A.2
Electrode Voltage Sensing (1)
67 lead
Work Voltage Sensing
21 lead
(2)
GMAW
GMAW-P
FCAW
GTAW
SMAW
67 lead required
67 lead required
67 lead required
Voltage sense at studs
Voltage sense at studs
21 lead optional (3)
21 lead optional (3)
21 lead optional (3)
Voltage sense at studs
Voltage sense at studs
(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.
FIGURE A.5
POWER
WAVE
S500
A
C
WORK
B
POWER WAVE ® S500
A-11 INSTALLATION
GENERAL GUIDELINES FOR VOLTAGE
SENSE LEADS
Sense leads should be attached as close to the weld as practical and out of the weld current path when possible. In extremely sensitive applications it may be necessary to route cables that contain the sense leads away from the electrode and work welding cables.
Voltage sense lead requirements are based on the weld process. See Table A.2
.
ELECTRODE VOLTAGE SENSING
The remote ELECTRODE sense lead (67) is built into the 5-pin arclink control cable and is always connected to the wire drive feed plate when a wire feeder is present. Enabling or disabling electrode voltage sensing is application specific and automatically configured by the active weld mode.
CAUTION
If the auto sense lead feature is disabled and the weld polarity attribute is improperly configured extremely high welding outputs may occur.
------------------------------------------------------------------------
WORK VOLTAGE SENSING
While most applications perform adequately by sensing the work voltage directly at the output stud, the use of a remote work voltage sense lead is recommended for optimal performance. The remote WORK sense lead (21) can be accessed through the four-pin voltage sense connector located on the control panel by using the K940 Sense Lead Kit. It must be attached to the work as close to the weld as practical, but out of the weld current path. For more information regarding the placement of remote work voltage sense leads, see
Voltage Sensing Considerations for Multiple Arc
Systems .
NEGATIVE ELECTRODE POLARITY
The Power Wave ® S500 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).
POWER WAVE ® S500
A-11
A-12
If Sense Leads ARE NOT Used:
INSTALLATION
VOLTAGE SENSING
CONSIDERATIONS FOR MULTIPLE
ARC SYSTEMS
Special care must be taken when more than one arc is welding simultaneously on a single part. Multiple arc applications do not necessarily dictate the use of remote work voltage sense leads, but they are strongly recommended.
If Sense Leads ARE Used:
A-12
• Position the sense leads out of the path of the weld current. Especially any current paths common to adjacent arcs. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources and result in arc interference.
• For longitudinal applications, connect all work leads at one end of the weldment and all of the work voltage sense leads at the opposite end of the weldment.
Perform welding in the direction away from the work leads and toward the sense leads. See Figure A.6.
• Avoid common current paths. Current from adjacent arcs can induce voltage into each others current paths that can be misinterpreted by the power sources and result in arc interference.
FIGURE A.6
DIRECTION
OF TRAVEL
CONNECT ALL SENSE
LEADS AT THE END
OF THE WELD.
CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.
POWER WAVE ® S500
A-13
POWER
SOURCE
#1
INSTALLATION
• For circumferential applications , connect all work leads on one side of the weld joint and all of the work voltage sense leads on the opposite side, such that they are out of the current path. See Figure A.7.
FIGURE A.7
POWER
SOURCE
#1
POWER
SOURCE
#2
POWER
SOURCE
#2
A-13
POWER
SOURCE
#1
POWER
SOURCE
#2
POWER WAVE ® S500
A-14 INSTALLATION
CONTROL CABLE CONNECTIONS
A-14
CONNECTION BETWEEN POWER
SOURCE AND ETHERNET NETWORKS
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 .
The Power Wave ® S500 is equipped with an IP67 rated
ODVA compliant RJ-45 Ethernet connector, which is located on the rear panel. All external Ethernet equipment (cables, switches, etc.), as defined by the connection diagrams, must be supplied by the customer. It is critical that all Ethernet cables external to either a conduit or an enclosure are solid conductor, shielded cat 5e cable, with a drain. The drain should be grounded at the source of 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.
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 tions.
® and Ethernet connec-
PRODUCT SPECIFIC INSTALLATION
INSTRUCTIONS
Connection Between Power Source and ArcLink ®
Compatible Wirefeeders (K1543, K2683 – ArcLink
Control Cable).
The 5-pin ArcLink control cable connects the power source to the wire feeder. The control cable consists of two power leads, one twisted pair for digital communication and one lead for voltage sensing. The 5-pin
ArcLink connection on the Power Wave ® S500 is located on the rear panel (See Case Back Controls in the
Operation section). The control cable is keyed and polarized to prevent improper connection. Best results will be obtained when control cables are routed separate from the weld cables, especially in long distance applications. The recommended combined length of the ArcLink control cable network should not exceed
200ft. (61.0m).
POWER WAVE ® S500
B-1 TABLE OF CONTENTS - OPERATION SECTION B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Power-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Graphic Symbols That Appear On This Machine Or In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Recommended Processes And Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Equipment Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Case Front Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Case Back Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Common Welding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Definition Of Welding Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Basic Welding Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6/B-8
POWER WAVE ® S500
B-2
SAFETY PRECAUTIONS
OPERATION B-2
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
WARNING
WARNING OR
CAUTION
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.
DANGEROUS
VOLTAGE
POSITIVE OUTPUT
NEGATIVE OUTPUT
HIGH TEMPERATURE
STATUS remove fumes from breathing zone.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body protection.
------------------------------------------------------------------------
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND in the FRONT OF THIS OPERATING MANUAL.
------------------------------------------------------------------------
POWER-UP SEQUENCE
When the Power Wave ® S500 is powered up, it can take as long as 30 seconds for the machine to be ready to weld. During this time period the user interface will not be active.
DUTY CYCLE
The duty cycle is based on a ten-minute period. A 40% duty cycle represents 4 minutes of welding and 6 minutes of idling in a ten-minute period. See the
Technical Specification section for the Power Wave ®
S500 ʼ s duty cycle ratings.
PROTECTIVE
GROUND
COOLER
OUTPUT
OPERATORS
MANUAL
WORK
CIRCUIT BREAKER
POWER WAVE ® S500
B-3
PRODUCT DESCRIPTION
OPERATION
RECOMMENDED EQUIPMENT
B-3
The Power Wave ® S500 is designed to be compatible with the current range of Power Feed™ systems including future versions of ArcLink ® feeders.
PRODUCT SUMMARY
The Power Wave ® S500 is a portable multi-process power source with high-end functionality capable of
Stick, DC TIG, MIG, Pulsed MIG and Flux-Cored welding. It is ideal for a wide variety of materials including aluminum, stainless and nickel — where arc performance is critical.
The Power Wave ® S500 is designed to be a very flexible welding system. Like existing Power Wave ʼ s ® , the software based architecture allows for future upgradeability. One significant change from the current range of Power Wave ® units is that the Ethernet communication feature is standard on the Power Wave ® S500 which allows for effortless software upgrades through
Powerwavesoftware.com. The Ethernet communication also gives the Power Wave ® S500 the ability to run
Production Monitoring™ 2. A Devicenet option allows the Power Wave ® S500 to be used in a wide range of configurations and the Power Wave ® S500 is designed to be compatible with advanced welding modules like
STT.
RECOMMENDED PROCESSES AND
EQUIPMENT
The Power Wave ® S500 is recommended for semiautomatic welding and may also be suitable for basic hard automation applications. The Power Wave ® S500 can be set up in a number of configurations, some requiring optional equipment or welding programs.
RECOMMENDED PROCESSES
The Power Wave ® S500 is a high speed, multi-process power source capable of regulating the current, voltage or power of the welding arc. With an output range of 5 to 550 amperes, it supports a number of standard processes including synergic GMAW, GMAW-P,
FCAW, FCAW-SS, SMAW, GTAW and GTAW-P on various materials especially steel, aluminum and stainless.
PROCESS LIMITATIONS
The software based weld tables of the Power Wave ®
S500 limit the process capability within the output range and the safe limits of the machine. In general the processes will be limited to .030 - .052 solid steel wire,
.030 - .045 stainless wire, .035 - 1/16 cored wire and
.035 - 1/16 Aluminum wire.
EQUIPMENT LIMITATIONS
Only ArcLink compatible semiautomatic wire feeders and users interfaces may be used. If other Lincoln wire feeders or non-Lincoln wire feeders are used there will be limited process capability and performance and features will be limited.
POWER WAVE ® S500
B-4
DESIGN FEATURES
LOADED WITH STANDARD FEATURES
• Multiple process DC output range: 5 - 550 Amps.
• 200 – 600 VAC, 3 phase, 50-60Hz input power.
• New and Improved Line Voltage Compensation holds the output constant over wide input voltage fluctuations.
• Utilizes next generation microprocessor control, based on the ArcLink ® platform.
• State of the art power electronics technology yields superior welding capability.
• Electronic over current protection.
• Input over voltage protection.
• F.A.N. (fan as needed). Cooling fan only runs when needed.
• Thermostatically protected for safety and reliability.
• Ethernet connectivity.
• Panel mounted Status and Thermal LED indicators facilitate quick and easy troubleshooting.
• Potted PC boards for enhanced ruggedness/reliability.
• Enclosure reinforced with heavy duty aluminum extrusions for mechanical toughness.
• Waveform Control Technology™ for good weld appearance and low spatter, even when welding nickel alloys.
• Sync Tandem installed.
OPERATION
CASE FRONT CONTROLS
B-4
See Figure B.1
1. USER INTERFACE (optional)
2. STATUS LED - (See Troubleshooting section for operational functions)
3. THERMAL LED - Indicates when machine has thermal fault.
4. POWER SWITCH - Controls power to the Power
Wave ® S500.
5. NEGATIVE WELD OUTPUT
6. POSITIVE WELD OUTPUT
7. WORK SENSE LEAD CONNECTOR
8. 12-PIN CONNECTOR (Optional)
1
2
3
4
FIGURE B.1
5 6 7 8
POWER WAVE ® S500
B-5
3
4
5
6
1
2
OPERATION
CASE BACK CONTROLS
(See Figure B.2)
1. 115 VAC CIRCUIT BREAKER
2. 115 VAC RECEPTACLES
3. RESERVED FOR FUTURE DEVELOPMENT
4. SYNC TANDEM/ STT CONNECTOR
5. Arclink CONNECTOR
6. DEVICENET KIT (optional)
7. ETHERNET
8. 40V CIRCUIT BREAKER
9. RESERVED FOR FUTURE DEVELOPMENT
10. GAS Solenoid Kit (optional)
FIGURE B.2
8
7
9
10
B-5
POWER WAVE ® S500
B-6 OPERATION
COMMON WELDING PROCEDURES BASIC WELDING CONTROLS
WARNING
MAKING A WELD
The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric
Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications and the build/user is and must be solely responsible for welding program selection.
Choose the electrode material, electrode size, shielding gas and process (GMAW, GMAW-P etc.) appropriate for the material to be welded.
Select the weld mode that best matches the desired welding process. The standard weld set shipped with the Power Wave ® S500 encompasses a wide range of common processes that will meet most needs. If a special weld mode is desired, contact a local Lincoln
Electric sales representative.
All adjustments are made through the user interface.
Because of the different configuration options your system may not have all of the following adjustments.
See Accessories section for Kits and Options available to use with the Power Wave ® S500.
DEFINITION OF WELDING MODES
B-6
AMPS
In constant current modes, this control adjusts the welding amperage.
VOLTS
In constant voltage modes, this control adjusts the welding voltage. NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all welding process variables to be set by the operator.
WELD MODE
Selecting a weld mode determines the output characteristics of the Power Wave ® power source. Weld modes are developed with a specific electrode material, electrode size and shielding gas. For a more complete description of the weld modes programmed into the Power Wave ® S500 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 ® S500 then uses the WFS setting to adjust the voltage and current according to settings contained in the POWER WAVE ® .
In non-synergic modes, the WFS control behaves like a conventional power source where WFS and voltage are independent adjustments. Therefore, to maintain proper arc characteristics, the operator must adjust the voltage to compensate for any changes made to the
WFS.
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.
TRIM
In pulse synergic welding modes, the Trim setting adjusts the arc length. Trim is adjustable from 0.50 to
1.50. 1.00 is the nominal setting and is a good starting point for most conditions.
ULTIMARC™ CONTROL
UltimArc™ Control allows the operator to vary the arc characteristics. UltimArc™ Control is adjustable from
–10.0 to +10.0 with a nominal setting of 0.0.
POWER WAVE ® S500
B-7
SMAW (STICK) WELDING
OPERATION
The welding current and Arc Force settings can be set through a Power Feed™ 10M or Power Feed™ 25M wire feeder. Alternatively an optional Stick / Tig UI can be installed into the power source to control these settings locally.
B-7
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 ® S500 automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range.
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.
NON SYNERGIC CV
In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS.
ALL CV MODES
Pinch adjusts the apparent inductance of the wave shape. The “pinch” function is inversely proportional to inductance. Therefore, increasing Pinch Control greater than 0.0 results in a crisper arc (more spatter) while decreasing the Pinch Control to less than 0.0
provides a softer arc (less spatter).
GTAW (TIG) WELDING
The welding current can be set through a Power
Feed™ 10M or Power Feed™ 25M wire feeder.
Alternatively an optional Stick / Tig UI can be installed into the power source to control these settings locally.
The TIG mode features continuous control from 5 to
550 amps with the use of an optional foot amptrol. The
Power Wave ® S500 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.
PULSE WELDING
Pulse welding procedures are set by controlling an overall “arc length” variable. When pulse welding, the arc voltage is highly dependent upon the waveform.
The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. Voltage or Trim can be adjusted.
Trim adjusts the arc length and ranges from 0.50 to
1.50 with a nominal value of 1.00. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the arc length. See Figure B.3.
FIGURE B.3
Trim .50
Arc Length Short
Trim 1.00
Arc Length Medium
Trim 1.50
Arc L ength Long
POWER WAVE ® S500
B-8 OPERATION
Most pulse welding programs are synergic. As the wire feed speed is adjusted, the Power Wave ® S500 will automatically recalculate the waveform parameters to maintain similar arc properties.
The Power Wave ® S500 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 ®
S500 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.
FIGURE B.4
UltimArc™ Control -10.0
Low Frequency, Wi de
UltimArc™ Control OFF
Med ium Fr equency and Wi dth
UltimArc™ Control +10.0
Hi gh Frequency , Fo cu sed
B-8
POWER WAVE ® S500
C-1 TABLE OF CONTENTS - ACCESSORIES SECTION C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Kits, Options And Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Factory Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2/C-3
POWER WAVE ® S500
C-2 ACCESSORIES
KITS, OPTIONS AND ACCESSORIES
K1842-10 10ft. Weld Power Cable
Coaxial Welding Cable
All Kits, Options and Accessories are found on the
Web site: ( www.lincolnelectric.com
)
C-2
Optimum weld cables for minimizing cable inductance and optimizing welding performance.
FACTORY INSTALLED OPTIONS
AWG 1/0 Coaxial Cables:
None Available
Order K1796-25 for 25 feet (7.6 m) cable length.
FIELD INSTALLED OPTIONS
Order K1796-50 for 50 feet (15.2 m) cable length.
GENERAL OPTIONS
Stick / Tig User Interface Kit
Mounts inside the front panel of the Power Wave ®
S500. Allows stick and Tig operation without having a wire feeder.
Order K3001-2
DeviceNet Kit
Mounts inside the back of the Power Wave ® S500.
Allows Devicenet objects to communicate with the
Power Wave ® S500.
Order K2827-1
Work Voltage Sense Lead Kit
Required to accurately monitor voltage at the arc.
Order K940-XX Series
Order K1811-XX Series
Deluxe Adjustable Gas Regulator & Hose Kit
Accommodates CO2, Argon or Argon-blend gas cylinders. Includes a cylinder pressure gauge, dual scale flow gauge and 4.3 ft. (1.3 m) gas hose.
Order K586-1
K2149-1 Work Lead Package
Order K1796-75 for 75 feet (22.9 m) cable length.
Order K1796-100 for 100 feet (30.5 m) cable length.
AWG #1 Coaxial Cables:
Order K2593-25 for 25 feet (7.6 m) cable length.
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable length.
K2909-1
12-pin to 6-pin adapter.
K2910-1
12-pin to 7-pin adapter.
Welding Fume Extractors
Lincoln offers a wide range of fume extraction environmental system solutions, ranging from portable systems easily wheeled around a shop to shop-wide central systems servicing many dedicated welding stations.
Request Lincoln publication E13.40
(See www.lincolnelectric.com
)
POWER WAVE ® S500
C-3
STICK OPTIONS
ACCESSORY KIT - 150 Amp
For stick welding. Includes 20 ft.
(6.1m) #6 electrode cable with lug,
15 ft. (4.6m) #6 work cable with lugs, headshield, filter plate, work clamp, electrode holder and sample pack of mild steel electrode.
ORDER K875
ACCESSORY KIT - 400 AMP
For stick welding. Includes 35 ft.
(10.7m) 2/0 electrode cable with lug,
30 ft. (9.1m) 2/0 work cable with lugs, headshield, filter plate, work clamp and electrode holder.
ORDER K704
REMOTE OUTPUT CONTROL
Permits remote adjustment of output.
Order K857-2 for 25 ft (7.6m) with 12 pin connector.
TIG OPTIONS
Pro-Torch™ TIG Torches
A full line of air-cooled and water-cooled torches available.
Request Lincoln publication E12.150
(See www.lincolnelectric.com
).
ACCESSORIES C-3
TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack
Get everything you need for TIG welding in one complete easy-to-order kit packaged in its own portable carrying case. Includes: PTA-17V torch, parts kit,
Harris ® flowmeter/regulator, 10 ft. (3.0 m) gas hose and work clamp and cable.
Order K2265-1
COMPATIBLE LINCOLN EQUIPMENT
Any Arclink compatible wire feeding equipment
(See www.lincolnelectric.com
).
Hand Amptrol ®
Provides 25 ft. (7.6 m) of remote current control for TIG welding.
Order K963-4 for Hand Amptrol with
12 pin connector.
Foot Amptrol ®
Provides 25 ft. (7.6 m) of remote current control for TIG welding.
Order K870-2 for Foot Amptrol with
12 pin connector.
POWER WAVE ® S500
C-4 NOTES C-4
POWER WAVE ® S500
D-1 TABLE OF CONTENTS - MAINTENANCE SECTION D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Calibration Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
POWER WAVE ® S500
D-2 MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
removed.
• Turn off power source before installing or servicing.
• Do not touch electrically hot parts.
• Turn the input power to the welding power source off at the fuse box before working in the terminal strip.
• Only qualified personnel should install, use or service this equipment.
------------------------------------------------------------------------
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing out the machine, using a low-pressure air stream, to remove accumulated dust and dirt from the intake and outlet louvers and the cooling channels in the machine.
PERIODIC MAINTENANCE
Calibration of the Power Wave ® S500 is critical for reliable operation. Generally speaking the calibration will not need adjustment. However, neglected or improperly calibrated machines may not yield satisfactory weld performance. To ensure optimal performance, the calibration of output Voltage and Current should be checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the factory. Generally, 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 Powerwave Manager to make the appropriate adjustments.
The calibration procedure itself requires the use of a grid and certified actual meters for voltage and current.
The accuracy of the calibration will be directly affected by the accuracy of the measuring equipment you use.
The Powerwave Manager includes detailed instructions and is available at: www.powerwavesoftware.com
.
POWER WAVE ® S500
D-2
D-3 MAINTENANCE
FIGURE D.1 – MAJOR COMPONENTS LOCATIONS
1. Case Front Assembly
2. Base & Power Conversion Assembly
3. Case Back Assembly
4. Roof Assembly
4
1
2
3
D-3
POWER WAVE ® S500
D-4 NOTES D-4
POWER WAVE ® S500
E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Line Switch, Input Board And Power Factor Control (PFC) Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Power Conversion Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Six Phase Chopper Board And Multi-Phase Output Choke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
DC Bus Board And Digital Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Optional Remote Control Board And 115VAC Inverter Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Thermal Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
Insulated Gate Bipolar Transistor (IGBT) Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
FIGURE E.1 BLOCK LOGIC DIAGRAM
FAN FAN
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
FAN SPEED
CONTROL
POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
40 VDC TO
PFC BOARD
DC
BUS
BOARD
40 VDC
MAIN
INPUT
SWITCH
INPUT
BOARD
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
SIX PHASE
CHOPPER BOARD
RELAY
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC 115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
ARCLINK
RECEPTACLE
+
-
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
POWER WAVE ® S500
E-2
MAIN
INPUT
SWITCH
RELAY
INPUT
BOARD
FAN FAN
FAN SPEED
CONTROL
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
THEORY OF OPERATION
FIGURE E.2 - GENERAL DESCRIPTION
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD
40 VDC TO
PFC BOARD POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
DC
BUS
BOARD
40 VDC
SIX PHASE
CHOPPER BOARD
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
ARCLINK
RECEPTACLE
+
-
E-2
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST
FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC
115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
GENERAL DESCRIPTION
The Power Wave ® S500 is a welder featuring an inverter type power source with Tribrid Converter
Technology and Automatic PowerConnect Technology.
It is a multi-process machine with high-end functionality capable of Stick, DC TIG, MIG, Pulsed MIG and
Flux-Cored welding. The Power Wave ® S500 regulates the current, voltage and power of the welding arc.
It also provides premier welding performance solutions for specific areas such as aluminum, stainless and nickel especially where machines size and weight are considerations. This machine is designed to be a very flexible welding power source. Like all machines in the
Power Wave product line the software based architecture allows for future upgradeability. An Ethernet port is standard which allows for effortless software upgrades through Powerwavesoftware.com. The
Ethernet communication also gives the Power Wave ®
S500 the ability to run Production Monitoring™ 2. The
Power Wave ® S500 is recommended for semiautomatic welding and may also be suitable for basic hard automation applications. It is compatible with the current range of Power Feed™ systems including future versions of ArcLink feeders.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-3 THEORY OF OPERATION
FIGURE E.3 - LINE SWITCH, INPUT BOARD AND POWER FACTOR CONTROL (PFC) BOARD
FAN FAN
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
40 VDC TO
PFC BOARD
FAN SPEED
CONTROL
POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
DC
BUS
BOARD
40 VDC
ARCLINK
RECEPTACLE
SIX PHASE
CHOPPER BOARD
+
INPUT
BOARD
E-3
MAIN
INPUT
SWITCH
RELAY
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
-
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST
FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC
115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
LINE SWITCH, INPUT BOARD AND
POWER FACTOR CONTROL (PFC)
BOARD
The Power Wave ® S500 can be connected to a variety of both three-phase or single-phase AC input voltages.
The Power Wave ® S500 automatically adjusts to operate with different AC input voltages. No reconnect switch settings are required. The initial input power is applied through a line switch located on the front panel of the machine. This AC input voltage is applied to an input board where it is rectified to a DC voltage. The
DC voltage is then applied to a soft-start circuit consisting of two PTC thermistors and two DC relays. This soft-start circuit limits the initial inrush current to the DC link capacitors to prevent damage to the input rectifier.
Two seconds after the input line switch is activated the two relays, which are in parallel with the thermistors, are closed thus applying the full input potential to the
DC link capacitor. The two DC relays are activated by the Power Factor Correction board.
The rectified input power is also connected to the
Power Factor Correction board. The PFC board receives this unregulated DC voltage and converts it to several DC supplies that are used to power the electronics housed on the PFC board. A 36VDC supply is also connected to the Digital Control Board.
The PFC board receives feedback information in the form of buck-boost currents, the 400VDC bus voltage, the rectified AC input voltage, the full bridge inverter currents and power module temperatures. The electronic circuits and firmware on the PFC board generate
Pulse Width Modulation (PWM) signals to regulate the
400VDC bus, drive the buck-boost circuit, shape the input current, drive the full bridge inverters and control the pre-charge relays.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-4
MAIN
INPUT
SWITCH
RELAY
INPUT
BOARD
THEORY OF OPERATION
FIGURE E.4 - POWER CONVERSION BOARD ASSEMBLY
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD FAN FAN
40 VDC TO
PFC BOARD
FAN SPEED
CONTROL
POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
DC
BUS
BOARD
40 VDC
SIX PHASE
CHOPPER BOARD
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
ARCLINK
RECEPTACLE
+
-
E-4
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST
FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC
115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
POWER CONVERSION BOARD
ASSEMBLY
Several circuits are located on the Power Conversion
Board. They are the two interleaved buck-boost converters, two full-bridge inverters, two planar transformers and a fan control circuit.
Buck-Boost Converters : The two Buck-Boost converters operate at 25 KHz. These converters convert the input voltage to a 400VDC bus. The PFC board regulates the Buck-Boost circuits to attain a very high power factor. If the rectified input voltage is greater or less than 400VDC, either the “Buck” portion or the
“Boost” portion of the circuitry will be active. The two
Buck-Boost circuits are driven by separate PWM signals from the PFC board.
Full Bridge Inverters : The 400VDC bus is applied to the two Full Bridge Inverters. The inverters operate at
50KHz. and are driven by two separate PWM signals generated from the PFC board. This PWM signals provide the inverter switches with a 98% on time. The outputs of the Full Bridge Inverters are applied to the primaries of the two Planar Transformers.
Planar Transformers : The primaries of the two Planar
Transformers are in parallel but are driven 90 degrees out of phase with each other. Both transformers have a 100 volt secondary winding for welding power. The outputs of these 100 volt windings are rectified and coupled to the six Phase Chopper Board. The lower
Planar Transformer has a 200 volt secondary winding that is used to power the 115VAC inverter board. The upper Planar Transformer has a 48 volt secondary winding that is rectified and filtered and is applied to the DC Bus board. The 48VDC is also used to power the fan speed control circuit.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-5
MAIN
INPUT
SWITCH
THEORY OF OPERATION
FIGURE E.5 - SIX PHASE CHOPPER BOARD AND MULTI-PHASE OUTPUT CHOKE
FAN FAN
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
40 VDC TO
PFC BOARD
FAN SPEED
CONTROL
POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
DC
BUS
BOARD
40 VDC
ARCLINK
RECEPTACLE
SIX PHASE
CHOPPER BOARD INPUT
BOARD
RELAY
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
+
-
E-5
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST
FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC
115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
SIX PHASE CHOPPER BOARD AND
MULTI-PHASE OUTPUT CHOKE
The Six Phase 20KHz. chopper is connected to the
100VDC bus that is generated by the two 100 volt secondary windings on the two planar transformers. The six high speed electronic switches are connected in parallel to the 100VDC bus. However, the gate drives are 60 degrees out of phase with independent PWMs drive signals received from the Digital Control Board.
The system is equivalent to a 120KHz. chopper. The output of the Six Phase Chopper is connected to the
Multi-Phase Output Choke. The Multi-Phase Output
Choke consists of three independent chokes with two windings on each choke core. Each choke coil is connected to one phase of the Six-Phase Chopper. This coupled inductor acts like a transformer providing low ripple current and low output inductance to the welding circuit. The output of the Multi-Phase Choke is connected to the negative output terminal.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-6
MAIN
INPUT
SWITCH
RELAY
INPUT
BOARD
THEORY OF OPERATION
FIGURE E.6 - DC BUS BOARD AND DIGITAL CONTROL BOARD
FAN FAN
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
40 VDC TO
PFC BOARD
FAN SPEED
CONTROL
POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
DC
BUS
BOARD
40 VDC
ARCLINK
RECEPTACLE
SIX PHASE
CHOPPER BOARD
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
+
-
E-6
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST
FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC
115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
DC BUS BOARD AND DIGITAL
CONTROL BOARD
The DC Bus Board receives 48VDC from the upper planar transformer. The DC Bus Board regulates and controls that 48VDC to a constant 40VDC output supply. The 40VDC is applied to the PFC control board, the Arclink receptacle and the Remote Control board.
The Digital Control Board receives commands and feedback information via various channels. It receives digital communications and commands from the PFC control board, the Remote Control board, the Device
Net connector and the RJ45 connector. The Digital
Control Board also receives and processes output voltage and output current data. It receives and sends output ”on” and fan “on” signals from the 115Volt
Inverter board. The Digital Control Board uses this feedback information and processes it with the digital commands it receives and sends the appropriate PWM signals to the Six Phase Chopper board to control the welding output. It also controls the optional gas solenoid and sends a signal to the Power Conversion board to control the speed of the two fans. The Digital
Control Board houses the software welding tables and monitors the thermostat circuitry.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-7
MAIN
INPUT
SWITCH
THEORY OF OPERATION
FIGURE E.7 - OPTIONAL REMOTE CONTROL BOARD AND 115VAC INVERTER BOARD
FAN FAN
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD
REMOTE
CONTROL
BOARD
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
40 VDC TO
PFC BOARD
FAN SPEED
CONTROL
POWER CONVERSION
P.C. BOARD ASSEMBLY
INPUT
CHOKE
TOP PLANAR
TRANSFORMERS
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
48 VDC
DC
BUS
BOARD
40 VDC
ARCLINK
RECEPTACLE
SIX PHASE
CHOPPER BOARD INPUT
BOARD
RELAY
RECTIFIED AND
FILTERED LINE
VOLTAGE
BUCK/BOOST
DRIVE
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
INPUT
CHOKE
BOTTOM PLANAR
TRANSFORMERS
200VAC
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
MULTI-PHASE
OUTPUT CHOKE
CURRENT
FEEDBACK
+
-
E-7
RECTIFIED
LINE VOLTAGE
40VDC FROM
DC BUS BOARD
+15VDC
RELAY
DRIVE
POWER FACTOR (PFC)
CONTROL BOARD
THERMAL
FAULT
BUCK-BOOST
FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
FAN
CONTROL
200VAC
115 VAC
P.C. BOARD
FAN ON
SIGNAL
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
OUTPUT
CONTROL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
DIGITAL CONTROL BOARD
CURRENT FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
RJ45
CONNECTOR
DEVICENET
CONNECTOR
VOLTAGE
SENSE
RECEPTACLE
OPTIONAL REMOTE CONTROL
BOARD AND 115VAC INVERTER
BOARD
The Remote Control Board receives information from the User Interface Board, the 12 pin receptacle, the
ArcLink receptacle and 40VDC from the DC Bus
Board. The Remote Control Board is the interface between an Arclink wirefeeder and the Power Wave ®
S500 machine. Trigger signals, digital communications and the 40VDC supply are all connected to the
Arclink wirefeeder through the Remote Control Board.
A Remote Output Control or a Foot Amptrol can also be connected through the 12 pin receptacle to the Remote
Control Board.
The 115VAC Inverter Board utilizes the 200VAC at
50KHz. received from the lower Planar Transformer to create and regulate the 115VAC at 60Hz. supply for the
115VAC receptacle.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-8 THEORY OF OPERATION
MACHINE PROTECTION
THERMAL PROTECTION
Three normally closed (NC) thermostats protect the machine from excessive operating temperatures. Two thermostats are located on the 115VAC heat sink and protect the 115VAC Inverter board from over-heating.
The third thermostat is located and integrated into the
Six Phase Chopper and is monitored by the Digital
Control board. Excessive temperatures may be caused by a lack of cooling air or by operating the machine beyond its duty cycle or output rating. If excessive operating temperatures should occur, the thermostats will prevent output from the machine. The yellow thermal light, located on the front of the machine, will be illuminated. The thermostats are selfresetting once the machine cools sufficiently. If the thermostat shutdown was caused by excessive output or duty cycle and the fans are operating normally, the power switch may be left on and the reset should occur within a 15-minute period. If the fans are not turning or the intake air louvers are obstructed, the power must be removed from the machine and the fan condition or air obstruction corrected.
E-8
PROTECTIVE CIRCUITS
Protective circuits are designed into the Power Wave ®
S500 to sense trouble and shut down the machine before damage occurs to the machine ʼ s internal components. Error Codes will be flashed out by the light on the front of the machine and will help identify the reason for the shutdown. Fault codes can also be seen by using the Diagnostic Software. Various status lights located on the PC boards aid in determining component status and diagnosing problems. See the
Troubleshooting section for more information regarding Error Codes.
OVER CURRENT PROTECTION
If the machine ʼ s welding output is shorted the Digital
Control board will limit the current to 375 amps.
POWER WAVE ® S500
E-9 THEORY OF OPERATION
FIGURE E.8 - INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
E-9 n + p n n + p +
SOURCE n +
DRAIN
A. PASSIVE
GATE
BODY REGION
DRAIN DRIFT REGION
BUFFER LAYER
INJECTING LAYER n + p n n + p +
SOURCE n +
DRAIN
B. ACTIVE
POSITIVE
VOLTAGE
APPLIED
GATE
BODY REGION
DRAIN DRIFT REGION
BUFFER LAYER
INJECTING LAYER
INSULATED GATE BIPOLAR TRAN-
SISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode. There is no gate signal, (zero volts relative to the source) and therefore, no current flow. The drain terminal of the IGBT may be connected to a voltage supply; but since there is no conduction, the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the
OFF position.
Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the source, is applied to the gate terminal of the IGBT, it is capable of conducting current. A voltage supply connected to the drain terminal will allow the IGBT to conduct and supply current to circuit components coupled to the source. Current will flow through the conducting
IGBT to downstream components as long as the positive gate signal is present. This is similar to turning ON a light switch.
PULSE WIDTH MODULATION
The term PULSE WIDTH MODULATION (PWM) is used to describe how much time is devoted to conduction. Changing the pulse width is known as MODULA-
TION. Pulse Width Modulation is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE ® S500
E-10 NOTES E-10
POWER WAVE ® S500
F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4/F-11
Case Cover Removal And DC Link Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
PFC Control Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Digital Control Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21
Optional User Interface Kit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Power Conversion Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
Multi-Phase Output Choke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-39
Current Transducer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
40 Volt DC Bus Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
Input Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53
Multi-Phase Chopper Board Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57
Current And Voltage Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-63
PFC Control Board Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-67
115 Volt Supply Board Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-71
40 Volt DC Bus Board Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-75
Line Switch Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-79
Input Board Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-83
Digital Control Board Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-87
Fan Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-91
Power Conversion Board Assembly Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . .F-95
Chopper Board Removal And Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-99
Retest After Repair Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-103
POWER WAVE ® S500
F-2 TROUBLESHOOTING AND REPAIR
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.
---------------------------------------------------------------------------------------------------------------------------
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 categories: output problems, ethernet problems and welding problems.
(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.
Symptoms are grouped into the following
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be conducted without removing the case wrap-around cover.
All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test points, components, terminal strips, etc. can be found on the referenced electrical wiring diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
F-2
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
POWER WAVE ® S500
F-3 TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.
F-3
- Remove the PC board from the static-shielding bag and place it directly into the equipment. Don ʼ t set the
PC board on or near paper, plastic or cloth which could have a static charge. If the PC board can ʼ t be installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers, don ʼ t remove them until installation is complete.
CAUTION
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.
Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.
4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.
2. Check for loose connections at the PC board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:
PC board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your body ʼ s static charge before opening the staticshielding bag. Wear an anti-static wrist strap. For safety, use a 1
Meg ohm resistive cord connected to a grounded part of the equipment frame.
- If you don ʼ t have a wrist strap, touch an un-painted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.
NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.
5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.
a. If the original problem does not reappear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks and terminal strips.
b. If the original problem is recreated by the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.
6. Always indicate that this procedure was followed when warranty reports are to be submitted.
NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.
- Tools which come in contact with the PC board must be either conductive, anti-static or static-dissipative.
POWER WAVE ® S500
F-4 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-4
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Major physical or electrical damage is evident when the Power Wave ®
S500 case is removed.
OUTPUT PROBLEMS
1. Contact your local authorized
Lincoln Electric Service Facility
1. Contact the Lincoln Electric
Service Department at 1-888-
935-3877.
The input fuses repeatedly fail or the input circuit breakers keep tripping.
1. Make certain the fuses or breakers are properly sized.
1. Perform the Input Board Test .
2. Perform the Power Conversion
Assembly Test .
2. The welding procedure may be drawing too much input current or the duty cycle may be too high. Reduce the welding current and/or reduce the duty cycle.
3. Check for error codes. See
Status LED Troubleshooting in this section.
3. Perform the PFC Control Board
Test .
The machine will not power up. No lights or displays. The machine appears to be off.
1. Make sure the proper input voltage is being applied to the machine (check fuses or breakers).
1. Check the input line switch for proper operation. Also check the associated leads for loose or faulty connections. See the
Wiring Diagram.
2. Make sure the input supply disconnect has been turned ON.
3. Make certain the input power line switch is in the ON position.
2. Check to make sure that 40VDC is being applied to the Optional
User Interface Board at lead
52D(+) to lead 51D(-). See the
Wiring Diagram.
4. Check for error codes. See
Status LED Troubleshooting in this section.
3. Perform the 40 Volt DC Bus
Board Test .
4. Perform the Input Board Test .
5. Perform the PFC Control Board
Test .
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-5 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-5
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The Power Wave ® S500 does not have welding output.
OUTPUT PROBLEMS
1. If the symptom is accompanied by an error code see the Status
LED Troubleshooting section.
2. There may be an external “short” in the external output circuitry.
Remove all loads from the output terminals and restart the machine.
3. If the thermal LED is lit the unit may be overheated. Adjust the welding load and /or duty cycle to coincide with the output limits of the Power Wave ® S500. Also see the symptom “The Thermal LED is ON” in this section.
1. Perform the Input Board Test .
2. Perform the Power
Conversion Assembly Test .
3. Perform the Digital Control
Board Test .
4. Perform the 40 Volt DC Bus
Board Test .
5. Perform the Optional User
Interface Kit Test .
6. Perform the Multi-Phase
Output Choke Test .
The Thermal LED is ON. The machine regularly overheats. There is no welding output.
1. The welding application may be exceeding the recommended duty cycle and/or current limits of the machine.
1. Check the thermostats and associated wiring for loose or faulty connections. See the
Wiring Diagram.
2. Dirt and dust may have clogged the cooling channels inside the machine. See the Maintenance
Section of this manual.
3. The air intake and exhaust louvers may be blocked due to inadequate clearance around the machine.
2. Check the DC voltage being applied to the fans. There should be 48VDC at lead 351 (-) to lead 353 (+). See the Wiring
Diagram.
4. Make sure the fans are functioning correctly. The fans will run at variable speeds dependent upon the temperature of the
Buck/Boost heat sinks. The fans should also run at a high speed if a thermostat has tripped.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-6 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-6
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The “Real Time Clock” no longer functions.
OUTPUT PROBLEMS
1. The Digital Control Board Battery may be faulty.
Battery may be faulty. Replace if necessary (Type BS2032).
2. The Digital Control Board may be faulty.
3. Perform the Digital Control
Board Test .
The Power Wave ® S500 will not produce full output.
1. The input voltage may be too low. Check for error codes. See
Status LED Troubleshooting in this section.
2. Make certain the three-phase input voltage is correct for the machine.
1. Perform the Current Transducer
Test .
2. Perform the Current and
Voltage Calibration Procedure .
3. Perform the Digital Control
Board Test .
4. Perform the Power Conversion
Assembly Test .
5. Perform the Multi-Phase Output
Choke Test .
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-7 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-7
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
General degradation of the welding performance
WELDING PROBLEMS
1. Check for proper wire feeding.
Make certain that the actual speed is the same as the preset.
1. Perform the Current and
Voltage Calibration Procedure .
2. Verify that the correct wire drive and gear ratio have been selected.
3. Check the welding cables for loose or faulty connections.
4. Check for adequate gas shielding.
5. Make sure the welding process is correct for the wire feed and voltage settings.
The wire burns back to the tip at the end of the weld.
1. Reduce the burnback time.
2. Reduce the workpoint.
N/A.
During a weld the machine shuts down.
1. The secondary current limit has been exceeded and the machine shuts down to protect itself.
Adjust the procedure to reduce the load and lower the output current draw.
1. A non-recoverable internal fault will interrupt the welding output.
This condition will also result in a status light blinking. Check for error codes. See Status LED
Troubleshooting in this section.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-8 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-8
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The arc is excessively long and erratic.
WELDING PROBLEMS
1. In the wirefeeder make sure the correct wire drive and gear ratio have been selected for the welding process being used.
1. Perform the Current and
Voltage Calibration Procedure .
2. Make sure the shielding gas is correct for the welding process being used. Also make sure the flow rate is correct.
The welding starting is poor.
1. Make sure the driver roll tension on the wirefeeder is adjusted correctly. Also the welding wire should travel freely through wire feeding path. Check the welding tip for blockage.
N/A.
2. Make sure the shielding gas flow is correct.
The end of the weld is not acceptable.
1. Make sure all of the settings for
Burnback and Crater states are set correctly for the welding process being used. Verify that the Burnback has a value other than 0.
N/A.
2. Verify the burnback set points for workpoint, trim and wave values.
3. Make sure the shielding gas flow is adequate.
The ArcLink wirefeeder will not power up.
1. Check the ArcLink cable connecting the Power Wave ® S500 to the ArcLink wirefeeder.
1. Perform the 40 Volt DC Bus
Board Test .
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-9 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The system will not connect.
F-9
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ETHERNET PROBLEMS
1. Make sure that the correct patch cable or cross over cable is being used.
2. Make sure the software is not blocking the connection. See the on line Diagnostic Utility.
3. Verify that the cables are fully inserted into the bulk head connector.
4. Verify that the network device connected to the Power Wave is either a 10-baseT device or a
10/100-baseT device.
5. The LED located under the PC board Ethernet connector will be lit when the machine is connected to another network device.
1. Use Weld Manager (included on the Power Wave Utilities and available at www.powerwavesoftware.com
) to verify the correct IP address information has been entered.
2. Verify that no duplicate IP addresses exist on the network
The Ethernet connection drops out while welding.
1. Make sure all of the connections are tight and secure.
1. Make certain that the network cable is not located next to any heavy current carrying conductors. This would include input power cables and welding output cables.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-10 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
Error Code #
331 Instantaneous
Input Current Limit
INPUT CONTROL BOARD
Indication
Instantaneous input current limit has been exceeded. Typically indicates short term power overload.
334 Startup Current
Check Failure
335 Startup Voltage
Check Failure
336 Thermal Fault
Input current limit was exceeded during machine power-up.
Input voltage was too high or too low during machine power-up. Verify that the input voltage is between 200V and 650V.
Thermostat on primary module is tripped. Typically caused by a fan malfunction or blocked air vent. Check for proper air flow around and through the system. Verify that the thermal circuit has not been damaged or disconnected.
337 Precharge Timeout The DC bus voltage was not charged to a certain level at end of precharge.
338 Input Power Limit The input power drawn by the machine exceeded a safe level.
339 Current Imbalance
Fault
341 Input Voltage
Dropout
The current through the power modules is out of balance. Could indicate a faulty connection to a power module or a malfunctioning power module.
The input voltage momentarily dropped out. Check connections and verify quality of input power.
346 Transformer
Primary Overcurrent
Transformer current too high. Typically indicates short-term power overload.
347 Average Input
Current Limit
Average input current limit has been exceeded. Typically indicates short term power overload.
349 Bus Undervoltage The DC bus voltage dropped below the allowable limit.
Persistent errors require power to be cycled for the error to clear.
Temporary faults will go away on their own if the error condition is removed.
F-10
Type
Persistent
Persistent
Temporary
Temporary
Persistent
Persistent
Temporary
Temporary
Persistent
Persistent
Temporary
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-11 TROUBLESHOOTING AND REPAIR
Observe Safety Guidelines detailed in the beginning of this manual.
F-11
Error Code #
36 Thermal Error
MAIN CONTROL BOARD (“STATUS” LIGHT)
Indication
Indicates over temperature. Usually accompanied by thermal LED.
Check fan operation. Be sure process does not exceed duty cycle limit of the machine. Check for proper air flow around and through the system. Verify that the thermal circuit has not been damaged or disconnected.
45 Output Voltage High Welding voltage exceeded allowable limit. Check sense lead connection, voltage feedback circuits and voltage calibration. Verify that the machine is programmed with the latest firmware.
Type
Temporary
Persistent
52 DSP ADC Load High The control board DSP is experiencing a CPU overload. Verify that the machine is programmed with the latest firmware. If problem persists, perform the Control Board Removal And Replacement Procedure .
55 Communication with
DSP Failed
54 Secondary (Output)
Overcurrent Error
Communication with the control board DSP failed. Verify that the machine is programmed with the latest firmware. If problem persists, perform the Control Board Removal And Replacement Procedure .
The long-term average secondary (welding) current limit has been exceeded. NOTE: The long-term average secondary current limit is
325A (1 phase) or 575A (3 phase).
56 Chopper
Communication Error
58 Primary Fault
71 Secondary (Output)
Overpower Error
Indicates communication link between main control board and chopper has errors. Check the communication link between the control board and the chopper board. Isolate the machine from high-frequency noise.
Verify that the machine is programmed with the latest firmware. If problem persists, perform the Chopper Board Removal And Replacement
Procedure .
The PFC control board is not ready. Check that board for information on what error has occurred. Verify that the PFC board is connected to the control board. Verify that the machine is programmed with the latest firmware. If problem persists, perform the PFC Board Removal And
Replacement Procedure .
The long-term secondary (welding) power limit has been exceeded.
NOTE: The long-term average secondary current limit is 14 kW (1 phase) or 25 kW (3 phase).
73 FGEN ISR Overlap The control board DSP is experiencing a CPU overload. Verify that the machine is programmed with the latest firmware. If problem persists, perform the Control Board Removal And Replacement Procedure .
Persistent
Persistent
Temporary
Temporary
Temporary
Temporary
Temporary
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
POWER WAVE ® S500
F-12 NOTES F-12
POWER WAVE ® S500
F-13 TROUBLESHOOTING AND REPAIR
CASE COVER REMOVAL AND DC LINK
CAPACITOR DISCHARGE PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Case Covers and the discharging of the DC Link Capacitor.
MATERIALS NEEDED
5/16” Nutdriver
7/16” Wrench
25-1000 Ohm Resistor (25 Watts Minimum)
Volt/Ohmmeter
Insulated Gloves And Pliers
F-13
POWER WAVE ® S500
F-14 TROUBLESHOOTING AND REPAIR
CASE COVER REMOVAL AND DC LINK
CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.1 – CASE COVER REMOVAL
TOP CORNER
END CAPS
(4)
F-14
LEFT SIDE
MOUNTING SCREWS
(6)
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Using a 5/16” nutdriver, remove the four top corner end caps as shown in Figure F.1. Keep the screws and flat washers for reassembly.
3. Using a 5/16” nutdriver, remove the six remaining screws and washers from the left side to gain access to the left side internal components. See Figure F.1.
4. Locate the DC Link Capacitor and carefully check the voltage across it. The test probes should be carefully placed at the connection points B4 (+) and B5 (-). See Figure F.2
. If any voltage is present discharge the capacitor using the high wattage resistor (25-1000 ohms @25 watts minimum), electrically insulated gloves and pliers. CAUTION: Rectified and filtered input line voltage may be present. Hold the resistor terminals on the capacitor terminals for
10 seconds.
POWER WAVE ® S500
F-15 TROUBLESHOOTING AND REPAIR
CASE COVER REMOVAL AND DC LINK
CAPACITOR DISCHARGE PROCEDURE (continued)
FIGURE F.2 – CAPACITOR DISCHARGE PROCEDURE
F-15
HEAT SINK
TERMINAL
C19
DZ26
R54
R55
OCI1
D1
R52
LED5
BB
1
2
B56
J32
R70
D15
R31
DZ24
C11
LED4
J33
R1
R3
T3
B28
DZ3
LED3
C10
DZ23
R34
R35
T4
R61
D5
DZ4
R27
R2
FTP3
L3
B
29
C18
C17
R81
R79
D10
D11
R80
R78
B9
J35
C40
L2
C33
B6 X2
B18
R9
R68
C20
C36
C21
X1
B8
T5
L4
B7
C39
C2
FTP1
R28
DZ19
R37
B4
C7
T2
R65
D9
DZ13
DZ7
LED1
T1
C5
R41
R24
R23
J34
DZ14
R42
DZ8
D6
DZ6
DZ16
C3
R21
R22
C8
R25
R26
T6
C34
B16
C38
B5
5. Recheck the voltage across the B4 and B5 terminals. The voltage should be zero. If any voltage remains repeat the procedure.
NOTE: Any voltage present after discharge has been performed is an abnormal condition and may indicate a problem.
6. Check the DC voltage from B58 (+) to connection point B5 (-). If any voltage is present use the high wattage resistor (25-1000 ohms @25 watts minimum), electrically insulated gloves and pliers to discharge the 400VDC bus line.
B58 to B5. See Figure F.2.
7. Using a 5/16” nutdriver, remove the six remaining screws and washers from right cover to gain access to the right side portion of the unit.
8. Using a 7/16” wrench, remove the eight bolts from the lifting handles and remove the six screws to gain access to the top portion of the unit.
POWER WAVE ® S500
LEAD B5
LEAD B4
LEAD B58
F-16 TROUBLESHOOTING AND REPAIR
CASE COVER REMOVAL AND DC LINK
CAPACITOR DISCHARGE PROCEDURE (continued)
REPLACEMENT PROCEDURE
1. Using a 7/16” wrench, attach the eight bolts securing the lifting handles and attach the six screws to secure the top portion of the unit.
2. Using a 5/16” nutdriver, attach the six screws and washers securing the right side case cover.
3. Using a 5/16” nutdriver, attach the six screws and washers securing the left side case cover.
4. Using a 5/16” nutdriver, screws and flat washers previously removed, attach the four top corner end caps.
F-16
POWER WAVE ® S500
F-17 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the PFC Control Board is functioning correctly. There are very high voltages present on the PFC Control Board. This test will be limited to LED and audio error codes and also resistance and diode checks with the input power removed from the machine. This test will not test all of the circuits on the board.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
F-17
POWER WAVE ® S500
F-18 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD TEST (continued)
FIGURE F.3 – PFC CONTROL BOARD LOCATION
PFC CONTROL
BOARD
PFC BOARD
MOUNTING PANEL
FRONT PANEL
ASSEMBLY
F-18
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the PFC Control Board located on the inside of the front panel. See Figure F.3.
4. Carefully apply the correct input power to the
Power Wave ® S500 machine.
5. Check for the correct operation of the LED lights on the PFC Control Board. See Figure
F.4
and Tables F.1
and F.2
.
6. Remove the input power to the Power Wave ®
S500 machine and perform the Capacitor
Discharge Procedure .
7. If further testing is required, perform the PFC
Control Board Removal Procedure .
8. Perform the resistance and diode checks per
Table F.3, Table F.4
and Figure F.4
.
9. When testing is complete, perform the PFC
Control Board Replacement Procedure .
10. Perform the Case Cover Replacement
Procedure .
11. Perform Retest After Repair Procedure .
POWER WAVE ® S500
F-19 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD TEST (continued)
FIGURE F.4 – PFC CONTROL BOARD LED AND TEST POINTS
PIN 1 J23A PIN 16 LED2 J23B
J22
J21
J20
J23A
Q9
X1
Q2
C13
X13
C16
D5 D6
X2
C1
X8
C14
X14
FTP26
FTP15
X21
Q3 D49
OCI1
D26
FTP21
X31
X26
X27
FTP17
DZ19
X9
DZ20
FTP29
OCI5
D61
C33
D7
X3
C4
FTP9
D9
D10
X4
C5
T1
C6
FTP7
D11
C7
FTP8
D12 X5
D18 D19
X6
J23B
D20
OCI2
D27
X18 X19 X17 X16
D28
R257
OCI3
D29
Y2
J2
1
FTP5
LED2
LED5
1
J1
FTP6
FTP38
X10
FTP12
FTP11
FTP2
D36 D33 D35 D38 D34 D37
C29
D56
D57
C30
FTP40
D62
X24
LED1
Q8
OCI4
X20
X25
D51
C10
X12
Q1
X7
Q10
C20
C31
1
X29 X30 Q7
C32
D67 D66
4
6
Q6
C34
G6860-1
D69
R212
FTP3
PIN 1
J24
LED5
J25
J26
LED3 LED4 LED1
TABLE F.1 – PFC CONTROL BOARD LED DESCRIPTION AND FUNCTIONS
LED NUMBER
1
1
2
3
4
5
COLOR
GREEN
RED / FLASHING
RED
FUNCTION
Status is OK
Error Code (Blinking)
Fault on “B” side of bridge
GREEN
GREEN
-15VDC present
+15VDC present
RED Fault on “A” side of bridge
TABLE F.2 – PFC CONTROL BOARD ERROR CODES
ERROR CODE NUMBER
331
334
335
336
337
338
341
346
347
349
EXPLANATION
Peak input current limit
Start up current check failure
Start up voltage check failure
Thermal fault
Precharge failure
Input power limit
Input voltage drop-out
Transformer primary overcurrent
Average input current limit
Bus undervoltage
POWER WAVE ® S500
F-19
F-20 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD TEST (continued)
F-20
DESCRIPTION
TABLE F.3 – PFC CONTROL BOARD RESISTANCE CHECKS
INPUT POWER CIRCUIT
INPUT LINE SENSING
METER TEST POINTS
AND POLARITY
PLUG J26 PIN 4 (+)
TO
PLUG J26 PIN 6 (–)
PLUG J25 PIN 1 (+)
TO
PLUG J26 PIN 6 (–)
EXPECTED READINGS CONDITIONS
VERY HIGH RESIS-
TANCE. GREATER THAN
20,000 OHMS
VERY HIGH RESIS-
TANCE. GREATER THAN
500,000 OHMS
INPUT POWER
REMOVED. PLUG J26
REMOVED FROM PFC
BOARD
IF LOWER REPLACE
THE PFC BOARD
TABLE F.4 – PFC CONTROL BOARD DIODE CHECKS
DESCRIPTION
MAIN BUCK DRIVE “A”
AUX. BUCK DRIVE “A”
MAIN BOOST DRIVE “A”
MAIN BOOST DRIVE “A”
AUX. BOOST DRIVE “A”
AUX. BOOST DRIVE “A”
FULL BRIDGE “A”
FULL BRIDGE “A”
FULL BRIDGE “A”
FULL BRIDGE “A”
MAIN BUCK DRIVE “B”
AUX. BUCK DRIVE “B”
MAIN BOOST DRIVE “B”
MAIN BOOST DRIVE “B”
AUX. BOOST DRIVE “B”
AUX. BOOST DRIVE “B”
FULL BRIDGE “B”
FULL BRIDGE “B”
FULL BRIDGE “B”
FULL BRIDGE “B”
POSITIVE METER LEAD NEGATIVE METER LEAD EXPECTED READINGS
+/– 10%*
PLUG J23A PIN 8 PLUG J23A PIN 16 0.130VDC
PLUG J23A PIN 6
PLUG J23A PIN 12
PLUG J23A PIN 4
PLUG J23A PIN 11
PLUG J23A PIN 3
PLUG J24 PIN 7
PLUG J23A PIN 3
PLUG J24 PIN 3
PLUG J23A PIN 3
PLUG J23B PIN 1
PLUG J23B PIN 3
PLUG J23B PIN 13
PLUG J23B PIN 5
PLUG J23B PIN 14
PLUG J23B PIN 6
PLUG J24 PIN 6
PLUG J23B PIN 6
PLUG J24 PIN 2
PLUG J23B PIN 6
PLUG J23A PIN 14
PLUG J25 PIN 12
PLUG J23A PIN 12
PLUG J25 PIN 12
PLUG J23A PIN 11
PLUG J25 PIN 12
PLUG J24 PIN 7
PLUG J25 PIN 12
PLUG J24 PIN 3
PLUG J23B PIN 9
PLUG J23B PIN 11
PLUG J25 PIN 12
PLUG J23B PIN 13
PLUG J25 PIN 12
PLUG J23B PIN 14
PLUG J25 PIN 12
PLUG J24 PIN 16
PLUG J25 PIN 12
PLUG J24 PIN 2
NOTE: *An open or short indicates a faulty PFC Control Board.
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
0.130VDC
POWER WAVE ® S500
F-21 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Digital Control Board is receiving the correct input voltage and if the board is functioning correctly. This test will not test all of the circuits on the board.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
F-21
POWER WAVE ® S500
F-22 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD TEST (continued)
FIGURE F.5 – DIGITAL CONTROL BOARD LOCATION
F-22
DIGITAL CONTROL
BOARD
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Digital Control Board located on the underside of the top case panel. See Figure
F.5.
4. Locate Plugs J4, J5, J8, J9, J5 and J12 located on the Digital Control Board. See Figure F.6
.
See Wiring Diagram.
POWER WAVE ® S500
5. Care
fully apply the correct input voltage to the
Power Wave ® S500 machine.
6. Check for the correct operation of the LED lights on the Digital Control Board. See Figure
F.6
and Table F.5
.
7. Perform the voltage tests per Table F.6
. See
Figure F.6
.
8. Remove the input power to the Power Wave ®
S500 machine and perform the resistance checks per Table F.7
.
9. If the correct input voltage is being applied to the Digital Control Board and the correct output voltages are not being generated, the Digital
Control Board may be faulty.
10. If faulty, perform the Digital Control Board
Removal And Replacement Procedure .
11. Perform the Case Cover Replacement
Procedure .
12. Perform the Retest After Repair Procedure .
F-23 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD TEST (continued)
FIGURE F.6 – DIGITAL CONTROL BOARD LED AND TEST POINT LOCATIONS
J5 J6 LED 1 J7 LED 2 J8 J9
F-23
J12
LED 8
LED 7
D1 D3
J5
D4 D6
D2 D5
D8
Q1
X13
12
O
N
S3
O
N
S1
3
BT1
X83 X82 X29
Y1
X81
X28
Q24
Q25
Q11
Q10
J6
X4
X5
X99
X93 X98
X18
X33 Q16
11
X92
J7
6
X94 X96 X95 X97
X19
X34
Q3
X75
X100
X20
Q6
2
J8
6 7
J9
D16
X9
D17
X10
X22
C8
Q31 X38
X11
C6
Q14
X41 X25 X36 X85 X12
L14
Y2
X46
X53
DZ31
DZ32
O
N
S2
OCI5 OCI6
J11
R12
R15
R24
X67
X57
D35
J13
X48
L7
X49
Y3
X62
C255
Q20
OCI10 OCI9
C15
X64
X1
X59
Q18
OCI7 OCI8
Q19
D38 D39 D40 D41
X68
C11
J2
8
J4
1
X50
C12
C18
D42
R510
R6
R21
X35
FTP1
D54
X51
FTP3
LED9 C9
C10
T2
OCI12
X70
CT1
X63
D30
C14
C13
C19
Q22
C22
C20
C21
C292
X72
L11
Q23
L12
X73 X74
D19
D22
X26
X24
X21
LED 3, 4, 5, 6
J11 LED 10 J4 LED 9
LED NUMBER
1
2
3
6
7
8
4
5
9
10
TABLE F.5 – DIGITAL CONTROL BOARD LED DESCRIPTION AND FUNCTIONS
COLOR
GREEN
RED
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
GREEN
FUNCTION
STATUS IS OK
ERROR CODE (BLINKING)
WELDING OUTPUT ENABLED
SINGLE PHASE INPUT
ELECTRODE SENSE
WORK SENSE
ETHERNET LINK / ACTIVITY STATUS
ETHERNET SPEED STATUS
INPUT SUPPLY STATUS (30VDC TO 50VDC)
DEVICENET EXTERNAL 24VDC PRESENT
POWER WAVE ® S500
F-24 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD TEST (continued)
F-24
TABLE F.6 – DIGITAL CONTROL BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS
DESCRIPTION TEST POINTS LEAD NUMBERS CONDITIONS
INPUT SUPPLY FROM
PFC BOARD
EXPECTED
READING
40VDC
POWER FROM DIGITAL
CONTROL BOARD TO
CHOPPER BOARD
FAN CONTROL SIGNAL
POWER SUPPLY TO
CURRENT TRANSDUCER
POWER SUPPLY TO
CURRENT TRANSDUCER
SUPPLY TO OPTIONAL
INVERTER BOARD
J4 PIN 2
TO
J4 PIN 1
J12 PIN 12
TO
J12 PIN 3
J7 PIN 16
TO
J7 PIN 6
J8 PIN 6
TO
J8 PIN 2
J8 PIN 6
TO
J8 PIN 3
J8 PIN 7
TO
J4 PIN 8
LEAD 356 (–)
TO
LEAD 358 (+)
LEAD 348 (–)
TO
LEAD 344 (+)
LEAD 350 (–)
TO
LEAD 355 (+)
LEAD 214 (–)
TO
LEAD 212 (+)
LEAD 214 (–)
TO
LEAD 213 (+)
LEAD 417 (–)
TO
LEAD 416 (+)
5VDC
10VDC
+15VDC
-15VDC
15VDC
INPUT POWER
APPLIED TO
MACHINE
INPUT POWER
APPLIED TO
MACHINE
INPUT POWER
APPLIED AND FAN
RUNNING
INPUT POWER
APPLIED TO
MACHINE
INPUT POWER
APPLIED TO
MACHINE
INPUT POWER
APPLIED TO
MACHINE
TABLE F.7 – DIGITAL CONTROL BOARD RESISTANCE CHECKS AND EXPECTED READINGS
DESCRIPTION TEST POINTS LEAD NUMBERS CONDITIONS
CONNECTIONS TO
OUTPUT TERMINALS
CONNECTIONS TO
NORMALLY CLOSED
THERMOSTATS
J9 PIN 3
TO
NEGATIVE
OUTPUT
TERMINAL
J9 PIN 1
TO
POSITIVE
OUTPUT
TERMINAL
J5 PIN 2
TO
J5 PIN 3
LEAD 202
TO
NEGATIVE
OUTPUT
TERMINAL
LEAD 206
TO
POSITIVE
OUTPUT
TERMINAL
LEAD 410
TO
LEAD 409
EXPECTED
READING
ZERO OHMS
ZERO OHMS
ZERO OHMS
NO INPUT POWER
APPLIED TO
MACHINE
NO INPUT POWER
APPLIED TO
MACHINE
POWER WAVE ® S500
F-25 TROUBLESHOOTING AND REPAIR
OPTIONAL USER INTERFACE KIT TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Optional User Interface Kit is receiving the correct input voltage and if the boards are functioning correctly.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
F-25
POWER WAVE ® S500
F-26 TROUBLESHOOTING AND REPAIR
OPTIONAL USER INTERFACE KIT TEST (continued)
FIGURE F.7 – USER INTERFACE AND REMOTE INTERFACE BOARD LOCATIONS
F-26
OPTIONAL REMOTE
INTERFACE BOARD
OPTIONAL USER
INTERFACE BOARD
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Optional User Interface Kit Boards.
The User Interface Board is located on the front panel of the machine. See Figure F.7. The
Remote Interface Board is located on the underside of the roof panel.
4. Carefully apply the correct input power to the
Power Wave ® S500 machine.
POWER WAVE ® S500
5. Locate Plugs J114, J111, J112 and J115 on the
Remote Interface Board. See Figure F.8
. Also locate Plug J115 on the User Interface Board.
See Figure F.9
. See Wiring Diagram.
6. Carefully check for the expected voltages per
Table F.8
and Table F.9
.
7. If the correct input voltages are being applied to the Remote Interface Board and the correct outputs are not being generated, the Remote
Interface Board may be faulty.
8. If faulty, replace the Remote Interface Board.
9. If the correct voltages are present remove the input power and perform the resistance tests per Table F.10
. Also see the Wiring Diagram.
10. Perform the Case Cover Replacement
Procedure .
11. Perform the Retest After Repair Procedure .
F-27 TROUBLESHOOTING AND REPAIR
OPTIONAL USER INTERFACE KIT TEST (continued)
FIGURE F.8 – REMOTE INTERFACE BOARD TEST POINTS
J114 J111 J112
J115
J114
4 6
4
3
Q9
Q10
3
J111
6 7 8
X1
5 6
J112
4
J113
Q6
R22
R21
R19
Q2
C3
Q7
OCI1
G6948-1
Q4
Q3
Q5
DZ3
12 PIN
INTERFACE
1 2 3 4
FIGURE F.9 – USER INTERFACE BOARD TEST POINTS
F-27
POWER WAVE ® S500
3
4
1
2
J115
F-28 TROUBLESHOOTING AND REPAIR
OPTIONAL USER INTERFACE KIT TEST (continued)
F-28
DESCRIPTION
TABLE F.8 – VOLTAGE CHECKS ON REMOTE INTERFACE BOARD
40VDC BUS
SUPPLY FROM DC
BUSS BOARD
40VDC FROM
REMOTE
INTERFACE BOARD
TO S1 REMOTE
RECEPTACLE
40VDC FROM
REMOTE
INTERFACE BOARD
TO THE USER
INTERFACE BOARD
15VDC TRIGGER
SUPPLY FROM THE
DIGITAL CONTROL
BOARD
15VDC TRIGGER
SUPPLY FROM THE
REMOTE BOARD
15VDC TRIGGER
SUPPLY FROM
REMOTE BOARD
15VDC TRIGGER
SUPPLY FROM
REMOTE BOARD
15VDC TRIGGER
SUPPLY FROM
REMOTE BOARD
TEST POINT
METER PROBE (+)
PLUG J114 PIN 6
(LEAD 52C)
PLUG J111 PIN 8
(LEAD 52F)
PLUG J115 PIN 4
(LEAD 52D)
PLUG J112 PIN 6
(LEAD 373)
PLUG J111 PIN 6
(LEAD 2)
PLUG J111 PIN 6
(LEAD 2)
PLUG J112 PIN 4
(LEAD 372)
PLUG J112 PIN 4
(LEAD 372)
TEST POINT
METER PROBE (–)
PLUG J114 PIN 4
(LEAD 51C)
PLUG J111 PIN 7
(LEAD 51F)
PLUG J115 PIN 3
(LEAD 51D)
PLUG J112 PIN 5
(LEAD 370)
PLUG J111 PIN 3
(LEAD 4)
PLUG J111 PIN 3
(LEAD 4)
PLUG J112 PIN 5
(LEAD 370)
PLUG J112 PIN 5
(LEAD 370)
EXPECTED
READING
40VDC
40VDC
40VDC
12VDC
15VDC
0VDC
0VDC
15VDC
CONDITIONS
CORRECT INPUT
POWER APPLIED
TO MACHINE
CORRECT INPUT
POWER APPLIED
TO MACHINE
CORRECT INPUT
POWER APPLIED
TO MACHINE
CORRECT INPUT
POWER APPLIED
TO MACHINE
TRIGGER NOT
ACTIVATED (OPEN)
TRIGGER
ACTIVATED
(CLOSED)
TRIGGER NOT
ACTIVATED (OPEN)
TRIGGER
ACTIVATED
(CLOSED)
DESCRIPTION
40VDC SUPPLY
FROM REMOTE
BOARD
TABLE F.9 – VOLTAGE CHECKS ON USER INTERFACE BOARD
TEST POINT
METER PROBE (+)
PLUG J115 PIN 4
(LEAD 52D)
TEST POINT
METER PROBE (–)
PLUG J115 PIN 3
(LEAD 51D)
EXPECTED
READING
40VDC
CONDITIONS
CORRECT INPUT
POWER APPLIED
TO MACHINE
POWER WAVE ® S500
F-29 TROUBLESHOOTING AND REPAIR
OPTIONAL USER INTERFACE KIT TEST (continued)
DESCRIPTION
TABLE F.10 – RESISTANCE CHECKS
TEST POINT
METER PROBE
PLUG J111 PIN 5
(LEAD 75)
TEST POINT
METER PROBE
S1 RECEPTACLE
PIN C (LEAD 75)
EXPECTED
READING
ZERO OHMS CONTINUITY
CHECK FROM
PLUG J111 TO
12 PIN S1
RECEPTACLE
CONTINUITY
CHECK FROM
PLUG J111 TO
12 PIN S1
RECEPTACLE
CONTINUITY
CHECK FROM
PLUG J111 TO
12 PIN S1
RECEPTACLE
CONTINUITY
CHECK FROM
PLUG J115 ON
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
CONTINUITY
CHECK FROM
PLUG J115 ON
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
CONTINUITY
CHECK FROM
PLUG J115 ON
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
CONTINUITY
CHECK FROM
PLUG J115 ON
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
PLUG J111 PIN 4
(LEAD 76)
PLUG J111 PIN 1
(LEAD 77)
PLUG J115 PIN 1
(LEAD 53D)
PLUG J115 PIN 2
(LEAD 54D)
PLUG J115 PIN 3
(LEAD 51D)
PLUG J115 PIN 4
(LEAD 52D)
S1 RECEPTACLE
PIN D (LEAD 76)
S1 RECEPTACLE
PIN E (LEAD 77)
PLUG J115 PIN 1
(LEAD 53D)
PLUG J115 PIN 2
(LEAD 54D)
PLUG J115 PIN 3
(LEAD 51D)
PLUG J115 PIN 4
(LEAD 52D)
ZERO OHMS
ZERO OHMS
ZERO OHMS
ZERO OHMS
ZERO OHMS
ZERO OHMS
CONDITIONS
POWER TO
MACHINE
REMOVED
POWER TO
MACHINE
REMOVED
POWER TO
MACHINE
REMOVED
POWER TO
MACHINE
REMOVED
POWER TO
MACHINE
REMOVED
POWER TO
MACHINE
REMOVED
POWER TO
MACHINE
REMOVED
F-29
POWER WAVE ® S500
F-30 NOTES F-30
POWER WAVE ® S500
F-31 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the “power section” of the Power Conversion Assembly is functioning correctly. This test will NOT indicate if the entire PC board is functional.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
1/2" Wrench
F-31
POWER WAVE ® S500
F-32 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST (continued)
FIGURE F.10 – POWER CONVERSION ASSEMBLY LOCATION
POWER CONVERSION
ASSEMBLY
F-32
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Power Conversion Assembly located on the left side of the machine. See Figure
F.10.
4. Perform the Power Conversion diode tests per
Table F.11
and Figure F.11
. When diode test is complete make sure all internal leads are connected before applying input power to the machine .
POWER WAVE ® S500
5. Locate the five Green LEDs on the Power
Conversion Assembly. See Figure F.12
.
6. Carefully apply the correct three phase input power to the Power Wave ® S500 machine.
7. Check the Buck/Boost Circuits using the LED
Table F.12
. See Figure F.12
.
8. Perform the voltage checks. See Table F.13
and Figure F.12
.
9. Remove the input power to the Power Wave ®
S500 machine.
10. If any of the above test results are not correct the Power Conversion Assembly may be faulty.
11. If faulty, perform the Power Conversion
Board Assembly Removal and Replacement
Procedure .
12. Perform the Case Cover Replacement
Procedure .
13. Perform the Retest After Repair Procedure .
F-33 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST (continued)
F-33
TABLE F.11 – DIODE TESTS
NOTE: Make sure the input power is removed from the Power Wave ® S500 and the three leads are removed from terminal B56 and electrically isolated from each other. See Figure F.11
. When test is complete reconnect the three leads to terminal B56.
TEST DESCRIPTION
SIDE A BUCK IGBT
SIDE A BOOST IGBT
SIDE A HIGH
SPEED H-BRIDGE
SIDE B BUCK IGBT
SIDE B BOOST IGBT
SIDE B HIGH
SPEED H-BRIDGE
OUTPUT RECTIFIER
POSITIVE METER LEAD NEGATIVE METER LEAD
B13 B29
B28
B16
B5
B28
B28
B7
B18
B4
B15
B18
B18
B8
B58
B58
B16
B5
B17
B6
B58
B58
B4
B15
B11
B12
B9
B10
B57
B57
B57
B57
MEASURED LEAD
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.395 (+/– 10%)
0.335 (+/– 10%)
0.335 (+/– 10%)
0.335 (+/– 10%)
0.335 (+/– 10%)
POWER WAVE ® S500
B11
B12
B56
B58
B57
B10
B9
F-34 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST (continued)
FIGURE F.11 – POWER CONVERSION ASSEMBLY DIODE TEST POINTS
F-34
C19
DZ26
R54
R55
OCI1
D1
R52
LED5
B11
J32
XXXX
J33
R70
LED4
D15
R31
DZ24
C11
R1
R3
T3
DZ3
B28
LED3
T4
R61
D5
DZ4
C10
DZ23
R34
R35
B12
R27
R2
L3
FTP3
B13
X1
B29
B16
C38
B5
C21
C18
C40
B8
T5
C17
L2
C33
B56
L4
B7
R81
R79
D10
D11
R80
R78
B6
X2
B10
B18
R9
R68
C20
C36
B17
C2
FTP1
R28
DZ19
R37
B4
C39
B9
C7
XXXX
T2
R65
D9
DZ13
DZ7
LED1
T1
C5
R41
R24
R23
J35 J34
DZ14
R42
DZ8
C3
R21
R22
C8
D6
DZ6
DZ16
R25
R26
T6
C34
B15
B8
B6
B7
B17
B18
B4
B15
B13
B16
B5
POWER WAVE ® S500
F-35 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST (continued)
FIGURE F.12 – POWER CONVERSION ASSEMBLY VOLTAGE CHECK TEST POINTS
LED 4 J33 B28 LED 3 B29
F-35
LED 5
J37
LED 1
J32
R55
OCI1
D1
R52
C19
DZ26
R54
LED5
B11
XXXX
R70
D15
R31
DZ24
C11
LED4
R1
R3
T3
B12
J33
DZ3
B28
LED3
T4
R61
D5
DZ4
C10
DZ23
R34
R35
R27
R2
L3
FTP3
B13
X1
B29
B16
C38
B5
C21
C18
C40
B8
T5
C17
L2
C33
B56
L4
B7
R81
R79
D10
D11
R80
R78
B6 X2
B10
B18
R9
R68
C20
C36
B17
C2
FTP1
R28
DZ19
R37
B4
C39
B15 B9
C7
XXXX
T2
R65
D9
DZ13
DZ7
T1
C5
R41
LED1
R24
R23
J35 J34
DZ14
R42
DZ8
D6
DZ6
DZ16
C3
R21
R22
C8
R25
R26
T6
C34
B17
LED 2
B18
PIN 4
J37
PIN 9
PIN 13
J34
PIN 4
J34
PIN 1 PIN 6
PIN 10 PIN 14
J33
POWER WAVE ® S500
F-36 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST (continued)
LED NUMBER
LED 1
LED 2
LED 3
LED 4
LED 5
LED NUMBER
LED 1
LED 2
LED 3
LED 4
LED 5
TABLE F.12 – POWER CONVERSION LED LEGEND
DESCRIPTION
BOTTOM BOOST
IGBT DRIVE
BOTTOM BUCK
IGBT DRIVE
TOP BUCK
IGBT DRIVE
TOP BOOST
IGBT DRIVE
+48VDC AUXILIARY
CONDITIONS
INPUT POWER
(472VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(472VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(472VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(472VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(472VAC) APPLIED
AND MACHINE “ON”
DESCRIPTION
BOTTOM BOOST
IGBT DRIVE
BOTTOM BUCK
IGBT DRIVE
TOP BUCK
IGBT DRIVE
TOP BOOST
IGBT DRIVE
+48VDC AUXILIARY
CONDITIONS
INPUT POWER
(255VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(255VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(255VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(255VAC) APPLIED
AND MACHINE “ON”
INPUT POWER
(255VAC) APPLIED
AND MACHINE “ON”
LED STATUS
OFF
ON
ON
OFF
ON
LED STATUS
ON
ON
ON
ON
ON
F-36
POWER WAVE ® S500
F-37 TROUBLESHOOTING AND REPAIR
POWER CONVERSION ASSEMBLY TEST (continued)
F-37
DESCRIPTION
INPUT TO TOP
BUCK/BOOST
CIRCUIT
INPUT TO BOTTOM
BUCK/BOOST
CIRCUIT
OUTPUT OF
BUCK/BOOST
CIRCUITS
SUPPLY FOR THE
TOP BUCK/BOOST
LEM
SUPPLY FOR THE
TOP BUCK/BOOST
LEM
SUPPLY FOR THE
BOTTOM BUCK /
BOOST LEM
SUPPLY FOR THE
BOTTOM BUCK /
BOOST LEM
SUPPLY FOR THE
DC BUS BOARD
TABLE F.13 – POWER CONVERSION ASSEMBLY VOLTAGE TESTS
TEST POINT TEST POINT
B29(+) B28(–)
EXPECTED
READING
635VDC
B17(+)
J33 PIN 1 (+)
J33 PIN 6 (+)
J33 PIN 14 (+)
J34 PIN 13 (+)
J34 PIN 4 (+)
J37 PIN 4 (+)
B18(–)
J33 PIN 10 (–)
J33 PIN 10 (–)
J33 PIN 10 (–)
J33 PIN 10 (–)
J33 PIN 10 (–)
J37 PIN 9 (–)
635VDC
402VDC
+15VDC
–15VDC
+15VDC
–15VDC
+48VDC
CONDITIONS
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
472VAC INPUT AND
MACHINE “ON”
POWER WAVE ® S500
F-38 NOTES F-38
POWER WAVE ® S500
F-39 TROUBLESHOOTING AND REPAIR
MULTI-PHASE OUTPUT CHOKE TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Multi-Phase Choke Coils are not open and that they are not ground or shorted together.
MATERIALS NEEDED
7/16" Wrench
Volt/Ohmmeter
Wiring Diagram
F-39
POWER WAVE ® S500
F-40 TROUBLESHOOTING AND REPAIR
MULTI-PHASE OUTPUT CHOKE TEST (continued)
FIGURE F.13 – TEST COMPONENT LOCATIONS
F-40
MULTI-PHASE
OUTPUT CHOKE
MULTI-PHASE
CHOPPER BOARD
NEGATIVE
BUSS BAR
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Multi-Phase Chopper Board located on the lower right side of the machine. See
Figure F.13.
POWER WAVE ® S500
5. Using a 7/16” wrench, label and remove leads
BL1, BL2, BL3, BL4, BL5 and BL6 from the
Chopper Board. Save the bolts and lock washers for reassembly. See Figure F.14
. See
Wiring Diagram.
6. Label and remove the six Output Choke leads from the negative bus bar located near the left side front of the machine. See Figure F.13.
Note the choke leads are connected in pairs.
The same lead pairs must be reconnected to each other on the bus bar. See the Wiring
Diagram.
7. Check the continuity of each of the individual choke coils. See the Wiring Diagram. The resistance should be less than 0.5 ohms of resistance. Also when all the individual choke coils are separated they should NOT have continuity to each other. See the Wiring Diagram.
F-41 TROUBLESHOOTING AND REPAIR
MULTI-PHASE OUTPUT CHOKE TEST (continued)
FIGURE F.14 – MULTI-PHASE OUTPUT CHOPPER BOARD LEAD LOCATIONS
BL6
BL5
BL4
R75
5 D11
R77
R76
R79 R78
4 R7
R3
R1
R2
9 R2
C26
8 DZ1
5 D1
L9
L1
R34
C15
C16
R47
D112
R68
R69
R6
BL3
BL2
BL1
R71
0 R7
R73 R72
R4
R5
X19
C63
C74
D120
F-41
8. Check the individual choke coils to ground.
There should be a minimum of 500,000 ohms of resistance to ground.
9. When testing is complete reconnect all of the leads to the correct terminals and tighten securely.
10. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
F-42 NOTES F-42
POWER WAVE ® S500
F-43 TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Current Transducers are receiving the correct input voltages and if they are producing the correct feedback voltages.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
Laptop Computer
Power Wave Manager Software
Ethernet Cross Connect Cable (LE Co. #M19969-7)
Resistive Load Bank
Calibrated Ammeter
F-43
POWER WAVE ® S500
F-44 TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.15 – CURRENT TRANSDUCER TEST COMPONENT LOCATIONS
F-44
MULTI-PHASE
OUTPUT CHOKE
ASSEMBLY
CURRENT TRANSDUCER
OUTPUT CONTROL
FEEDBACK
CURRENT TRANSDUCER
MULTI-PHASE CHOPPER
FEEDBACK
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
4. Locate plug J8 on the Digital Control Board.
See Figure F.16
. See Wiring Diagram.
5. Locate plug J42 on the Mult-Phase Chopper
Board. See Figure F.17
. See Wiring Diagram.
6. Carefully apply the correct input power to the
Power Wave ® S500.
7. To check for the correct supply voltages perform the voltage checks on Table F.14
.
NOTE: Do not attempt to check the voltages at the current transducers ʼ connectors. The terminals are small and delicate and may be damaged if probed with meter leads. 1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the output choke located on the left front side of the machine. See Figure F.15. Also locate the two Current Transducers that are part of the output choke assembly.
POWER WAVE ® S500
F-45 TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.16 – DIGITAL CONTROL BOARD TEST POINTS
PIN 1 PIN 4
J8
J8
PIN 5 PIN 8
D1 D3
Q3 Q6
J5 J6
J7
J8
J9
D4 D6
D2 D5
X13
O
N
S3
O
N
S1
D8
Q1
Q24
Q25
Q11
X4
X5
X99
X93 X98
X18
X94 X96 X95 X97
X19
X75
X100
X20
D16
X9
D17
X10
C8
X22
Q31 X38
X11
C6
Q14
Q10 X41 X25 X36 X85 X12
X33 Q16 X34
X83 X82 X29
Y1
X81
X28
BT1
X92
L14
Y2
X46
X53
R12
R15
R24
DZ31 DZ32
O
N
S2
OCI5 OCI6
J11
X67
X57
D35
J13
X48
L7
X49
Y3
X62
C255
Q20
OCI10 OCI9
X1
X59
Q18
OCI7 OCI8
Q19
D38 D39 D40 D41
C15
X64
X68
C11
J2 J4
X50
C12
C18
D42
R510
R6
R21
X35
FTP1
D54
X51
FTP3
LED9 C9 C10 CT1
X63
D30
T2
C14
C13
OCI12
X70
C19
Q22
C22
C20
C21
C292
X72
L11
Q23
L12
X73 X74
D19
D22
X26
X24
X21
For the following steps refer to the information in the Diagnostic Utility found at
Powerwavemanager.com.
8. Using a Ethernet Cross Connect cable, connect a laptop computer to the Power Wave ® S500 via the Ethernet port located at the top rear of the machine.
9. Connect a resistive load bank (or 50 Ft. weld cable) to the positive and negative output terminals on the Power Wave ® S500 machine.
10. Using the Diagnostic Utility Software:
Establish communications with the Power
Wave ® S500.
Select the “Calibrate” tab.
Select the “50 amp” current set point.
Select “Turn Output On”.
Use an external calibrated ammeter that is not affected by inverter noise to read the actual current.
11. Check the current transducers ages. See Table F.15
.
CAUTION
ʼ feedback volt-
12. Repeat the test at several other current levels.
If the transducers ʼ feedback voltages ʼ are correct for the actual current, the transducers are functioning properly. If there is no feedback check the connections between the current transducers and the PC boards. See the
Wiring Diagram.
If using a weld cable across the output terminals instead of a resistive load bank, do not exceed the current rating of the cable.
-------------------------------------------------------------------
POWER WAVE ® S500
F-45
F-46 TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
FIGURE F.17 – MULTI-PHASE CHOPPER BOARD TEST POINTS
R7
D11
R77
R76
R7
R3
R2
R79 R78
D11
R68
R69
R6
R1
R71
R70
R5
R73 R72
R4
X19
R29
C26
DZ1
D1
C15
C16
R47
L1
R3
C6
C74
D120
J42
PIN 3
PIN 4
PIN 1
PIN 2
F-46
13. If the supply voltages are correct per Table
F.14
but the transducers ʼ feedback voltages are incorrect the current transducer or wiring from the current transducer to the PC board may be faulty.
14. When testing is complete Click “Turn Output
Off”.
15. Disconnect the laptop computer.
16. Remove the input power to the Power Wave ®
S500 machine.
17. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
F-47 TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
F-47
DESCRIPTION
TABLE F.14 – CURRENT TRANSDUCERS SUPPLY VOLTAGE CHECKS
TEST POINT TEST POINT EXPECTED
READING
+15VDC SUPPLY VOLTAGE
TO MULTI-PHASE
CHOPPER
TRANSDUCER
SUPPLY VOLTAGE
TO MULTI-PHASE
CHOPPER
TRANSDUCER
SUPPLY VOLTAGE
TO OUTPUT
CONTROL
TRANSDUCER
SUPPLY VOLTAGE
TO OUTPUT
CONTROL
TRANSDUCER
J42 PIN 1 LEAD 216 J42 PIN 4 LEAD 218
J42 PIN 2 LEAD 217 J42 PIN 4 LEAD 218
J8 PIN 2 LEAD 212
J8 PIN 3 LEAD 213
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
–15VDC
+15VDC
–15VDC
CONDITIONS
MACHINE “ON”
MACHINE “ON”
MACHINE “ON”
MACHINE “ON”
POWER WAVE ® S500
F-48 TROUBLESHOOTING AND REPAIR
CURRENT TRANSDUCER TEST (continued)
TABLE F.15 – CURRENT TRANSDUCERS FEEDBACK VOLTAGE CHECKS
MULTI-PHASE CHOPPER TRANSDUCER
OUTPUT CURRENT
(AMPS)
500
450
400
350
300
250
200
150
100
50
TEST POINT
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
J42 PIN 3 LEAD 215
TEST POINT
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
J42 PIN 4 LEAD 218
EXPECTED
READING
4.0VDC
3.6VDC
3.2VDC
2.8VDC
2.4VDC
2.0VDC
1.6VDC
1.2VDC
0.8VDC
0.4VDC
OUTPUT CONTROL TRANSDUCER
TEST POINT TEST POINT OUTPUT CURRENT
(AMPS)
500
450
400
350
300
250
200
150
100
50
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 1 LEAD 211
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
J8 PIN 6 LEAD 214
EXPECTED
READING
4.0VDC
3.6VDC
3.2VDC
2.8VDC
2.4VDC
2.0VDC
1.6VDC
1.2VDC
0.8VDC
0.4VDC
F-48
POWER WAVE ® S500
F-49 TROUBLESHOOTING AND REPAIR
40 VOLT DC BUS BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the 40 Volt DC Bus Board is receiving the correct input voltage and if the board is functioning correctly.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
F-49
POWER WAVE ® S500
F-50 TROUBLESHOOTING AND REPAIR
40 VOLT DC BUS BOARD TEST (continued)
FIGURE F.18 – 40 VOLT DC BUS BOARD LOCATION
F-50
40 VOLT DC
BUS BOARD
PROCEDURE
WARNING
6. If the red LED is lit, the DC Bus Board is receiving 48VDC voltage from the Power Conversion
Assembly.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
7. If the red LED is blinking, carefully remove plug
J47 from the DC Bus Board. See Figure F.19
.
If the blinking stops and the red LED stays lit and steady, this is an indication of a heavy load on the 40VDC output line. See the Wiring
Diagram.
• Always wear dry insulating gloves.
8. If the red LED is not lit check circuit breaker
CB2 located on the case back. Reset if tripped.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
9. Perform the voltage tests per Table F.16
. See
Figure F.19
.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
10. If the correct input voltage is being applied to the DC Bus Board and the correct output voltages are not being generated, the DC Bus
Board is faulty.
3. Locate the DC Bus Board located on the lower right side of the machine. See Figure F.18.
4. Carefully apply the correct input power to the
Power Wave ® S500 machine.
5. Locate the red LED on the DC Bus Board. See
Figure F.19
. See Wiring Diagram.
11. If faulty, perform the 40 Volt DC Bus Board
Removal and Replacement Procedure .
12. Perform the Case Cover Replacement
Procedure .
13. Perform the Retest After Repair Procedure .
POWER WAVE ® S500
F-51 TROUBLESHOOTING AND REPAIR
40 VOLT DC BUS BOARD TEST (continued)
FIGURE F.19 – 40 VOLT DC BUS BOARD TEST POINTS
LEAD
#52
LEAD
#51A
LEAD
#52A
RED
LED
LEAD
#66
J47
LEAD
#51
J48
LEAD
#65A
F-51
L15732-1
TABLE F.16 – 40 VOLT DC BUS BOARD TEST POINTS AND EXPECTED READINGS
DESCRIPTION TEST POINT TEST POINT
PLUG J48 PIN 1 (+)
LEAD #65A
PLUG J48 PIN 3 (–)
LEAD #66
EXPECTED
READING
48VDC INPUT FROM THE
POWER CONVERSION
ASSEMBLY
40VDC OUTPUT TO
ArcLink RECEPTACLE
40VDC OUTPUT TO
PFC CONTROL BOARD
PLUG J47 PIN 8 (+)
LEAD #52A
PLUG J47 PIN 4 (+)
LEAD #52
PLUG J47 PIN 1 (+)
LEAD #51A
PLUG J47 PIN 5 (+)
LEAD #51
40VDC
40VDC
POWER WAVE ® S500
F-52 NOTES F-52
POWER WAVE ® S500
F-53 TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Input Board is receiving the correct input voltage and if the board is functioning correctly.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
F-53
POWER WAVE ® S500
F-54 TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST (continued)
FIGURE F.20 – INPUT BOARD LOCATION
F-54
INPUT
BOARD
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Input Board located on the upper right side of the machine. See Figure F.20.
NOTE: To gain access to the Input Board the insulating cover will have to be removed. Cut the three cable ties securing the insulating cover.
4. Perform the Input Board diode checks per
Table F.17
and Figure F.21
.
POWER WAVE ® S500
5. Locate the Green LED on the Input Board. See
Figure F.21
. See Wiring Diagram.
6. Carefully apply the correct three phase input power to the Power Wave ® S500 machine.
7. If the Green LED is lit, the Input Board is receiving input power. See Figure F.21
.
8. If the Green LED is not lit, the Input Board is not receiving input power.
9. Carefully perform the voltage tests per Table
F.18
. See Figure F.21
.
10. If the correct input voltage is being applied to the Input Board and the correct output voltages are not being generated the Input Board may be faulty.
11. If faulty, perform the Input Board Removal and Replacement Procedure . Be sure to replace the insulating cover on the Input Board.
12. Perform the Case Cover Replacement
Procedure .
13. Perform the Retest After Repair .
F-55
DESCRIPTION
SMALL 3-PHASE
RECTIFIER
SMALL 3-PHASE
RECTIFIER
SMALL 3-PHASE
RECTIFIER
SMALL 3-PHASE
RECTIFIER
SMALL 3-PHASE
RECTIFIER
SMALL 3-PHASE
RECTIFIER
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
LARGER 3-PHASE
BRIDGE
TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST (continued)
TABLE F.17 – INPUT BOARD DIODE CHECKS
TEST POINT
METER PROBE (+)
B1
B2
B3
J1 PIN 3 ON BOARD
PLUG REMOVED
J1 PIN 3 ON BOARD
PLUG REMOVED
J1 PIN 3 ON BOARD
PLUG REMOVED
B1
TEST POINT
METER PROBE (–)
J1 PIN 3 ON BOARD
PLUG REMOVED
J1 PIN 3 ON BOARD
PLUG REMOVED
J1 PIN 3 ON BOARD
PLUG REMOVED
B1
B2
B3
B4
B2
B3
B4
B4
B4
B4
B1
B2
B1
B2
B3
B4
B5
B5
B5
B3
B1
B2
B3
B5
B5
B5
.511V
.511V
OPEN
OPEN
OPEN
.470V
.470V
.470V
EXPECTED
READING
.578V
.578V
.578V
OPEN
OPEN
OPEN
.511V
OPEN
OPEN
OPEN
F-55
POWER WAVE ® S500
F-56
B4
TROUBLESHOOTING AND REPAIR
INPUT BOARD TEST (continued)
FIGURE F.21 – INPUT BOARD TEST POINT LOCATION
10 6
J1
J1
R6
5 1
R3 R7
J1
CR1
GREEN
LED
B3
B2
D6
CR2
B1
F-56
B5
TABLE F.18 – INPUT BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS
(NOMINAL 460VAC APPLIED)
DESCRIPTION TEST POINT TEST POINT
THREE-PHASE INPUT
THREE-PHASE INPUT
THREE-PHASE INPUT
DC TO POWER
CONVERSION BOARD
FILTERED DC TO
PFC BOARD
RECTIFIED AC TO
PFC BOARD
DC POWER TO RELAYS
CR1 AND CR2 FROM
PFC BOARD
B1
B2
B3
B4(+)
PLUG J1 PIN 6
(LEAD 366) (+)
PLUG J1 PIN 3
(LEAD 369) (+)
PLUG J1 PIN 10
(LEAD 362) (+)
B2
B3
B1
B5(–)
B5(–)
B5(–)
PLUG J1 PIN 5
(LEAD 367) (–)
EXPECTED
READING
AC LINE VOLTAGE
(Ex. 470VAC)
AC LINE VOLTAGE
(Ex. 470VAC)
AC LINE VOLTAGE
(Ex. 470VAC)
AC LINE VOLTAGE X
1.414 +/–10%
(Ex. 629V
D
C)
AC LINE VOLTAGE X
1.414 +/–10%
(Ex. 648V
D
C)
AC LINE VOLTAGE X
1.414 +/–10%
(Ex. 629V
D
C)
15VDC
POWER WAVE ® S500
F-57 TROUBLESHOOTING AND REPAIR
MULTI-PHASE CHOPPER BOARD TEST
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will help determine if the Multi-Phase Chopper Board is receiving the correct input voltage and if the board is functioning correctly.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
F-57
POWER WAVE ® S500
F-58 TROUBLESHOOTING AND REPAIR
MULTI-PHASE CHOPPER BOARD TEST (continued)
FIGURE F.22 – MULTI-PHASE CHOPPER BOARD LOCATION
F-58
MULTI-PHASE
CHOPPER BOARD
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input power to the Power Wave ®
S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Multi-Phase Chopper Board located on the lower right side of the machine. See
Figure F.22.
POWER WAVE ® S500
4. Perform the Multi-Phase Chopper Board diode checks per Table F.19
and Figure F.23
.
5. Locate the Green LED on the Multi-Phase
Chopper Board. See Figure F.23
. See Wiring
Diagram.
6. Carefully apply the correct three phase input power to the Power Wave ® S500 machine.
7. If the Green LED is lit, the Multi-Phase Chopper
Board is receiving input power from the Power
Conversion Assembly (100VDC). See Figure
F.23
.
8. If the Green LED is not lit, the Multi-Phase
Chopper Board may not be receiving the
100VDC from the Power Conversion Board.
See the Wiring Diagram.
F-59
BL3
BL2
BL1
B2
BL6
BL5
BL4
TROUBLESHOOTING AND REPAIR
MULTI-PHASE CHOPPER BOARD TEST (continued)
FIGURE F.23 – MULTI-PHASE CHOPPER BOARD TEST POINTS
R75
D115
R77
R76
4 R7
R3
R2
R79 R78
D112
R68
R69
R6
R1
R71
0 R7
R5
R73 R72
R4
9 R2
C26
8 DZ1
5 D1
L9
L1
R34
C15
C16
R47
X19
C63
C74
D120
F-59
6 LEDS
(GATE FIRING)
GREEN LED
B1
9. Energize the output of the Power Wave ® S500 machine. Check to make sure the six LEDs on the Multi-Phase Control board are lit. This is an indication that the Multi-Phase Control board is receiving gate firing signals from the Control
Board and the Multi-Phase board is providing gate driving signals to the Multi-Phase Chopper board. See Figure F.23.
10. Carefully perform the voltage tests per Table
F.20
. See Figure F.23.
11. If the correct input voltage is being applied to the Multi-Phase Chopper Board and the correct output voltages are not being generated, the
Multi-Phase Chopper Board may be faulty.
12. If faulty, perform the Chopper Board Removal and Replacement Procedure .
13. Perform the Case Cover Replacement
Procedure .
14. Perform the Retest After Repair Procedure .
POWER WAVE ® S500
F-60 TROUBLESHOOTING AND REPAIR
MULTI-PHASE CHOPPER BOARD TEST (continued)
F-60
TABLE F.19 – MULTI-PHASE CHOPPER BOARD DIODE CHECKS
NOTE: Prior to testing make sure the input power is removed from the Power Wave ® S500 machine and that all leads are removed from terminals B1 and B2 on the Multi-Phase Chopper Board. See Figure F.23
.
DESCRIPTION CONDITIONS
PHASE 3 DRIVER
TEST POINT
METER PROBE (+)
B2
TEST POINT
METER PROBE (–)
BL1
EXPECTED
READING +/–10%
.413V
PHASE 2 DRIVER
PHASE 1 DRIVER
PHASE 6 DRIVER
PHASE 5 DRIVER
PHASE 4 DRIVER
B2
B2
B2
B2
B2
BL2
BL3
BL4
BL5
BL6
ALL LEADS
REMOVED FROM
B1 AND B2
ALL LEADS
REMOVED FROM
B1 AND B2
ALL LEADS
REMOVED FROM
B1 AND B2
ALL LEADS
REMOVED FROM
B1 AND B2
ALL LEADS
REMOVED FROM
B1 AND B2
ALL LEADS
REMOVED FROM
B1 AND B2
.413V
.413V
.413V
.413V
.413V
POWER WAVE ® S500
F-61 TROUBLESHOOTING AND REPAIR
MULTI-PHASE CHOPPER BOARD TEST (continued)
F-61
TABLE F.20 – MULTI-PHASE CHOPPER BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS
MODE TEST POINT (+) TEST POINT (–)
TIG
TIG
TIG
TIG
TIG
TIG
TIG
MODE
CV
CV
CV
CV
CV
CV
CV
MODE
STICK
STICK
STICK
STICK
STICK
STICK
STICK
OPEN CIRCUIT
VOLTAGE
24VDC
24VDC
24VDC
24VDC
24VDC
24VDC
24VDC
OPEN CIRCUIT
VOLTAGE
70VDC
70VDC
70VDC
70VDC
70VDC
70VDC
70VDC
OPEN CIRCUIT
VOLTAGE
60VDC
60VDC
60VDC
60VDC
60VDC
60VDC
60VDC
B1
BL1
BL2
BL3
BL4
BL5
BL6
TEST POINT (+)
B1
BL1
BL2
BL3
BL4
BL5
BL6
TEST POINT (+)
B1
BL1
BL2
BL3
BL4
BL5
BL6
B2
B2
B2
B2
B2
B2
B2
TEST POINT (–)
B2
B2
B2
B2
B2
B2
B2
TEST POINT (–)
B2
B2
B2
B2
B2
B2
B2
EXPECTED
READING (+/–10%)
97VDC
73VDC
73VDC
73VDC
73VDC
73VDC
73VDC
EXPECTED
READING (+/–10%)
97VDC
26VDC
26VDC
26VDC
26VDC
26VDC
26VDC
EXPECTED
READING (+/–10%)
97VDC
36VDC
36VDC
36VDC
36VDC
36VDC
36VDC
POWER WAVE ® S500
F-62 NOTES F-62
POWER WAVE ® S500
F-63 TROUBLESHOOTING AND REPAIR
CURRENT AND VOLTAGE CALIBRATION PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in checking and if necessary, adjusting the calibration of the Power Wave ® S500.
Calibration should be checked as part of the Retest After Repair Procedure .
F-63
MATERIALS NEEDED
Power Wave Manager Utilities Software (www.powerwavemanager.com)
Laptop or other Suitable Computer
Ethernet Cross Connect Cable (LECO #M19969-7)
Resistive Load Bank
Two (2) Welding Cables - 20ft. -4/0
Calibrated Ammeter and Voltmeter *
* Calibration inaccuracies due to external metering can and will effect weld performance. Use good quality digital meters that are calibrated and traceable to
National Standards.
POWER WAVE ® S500
F-64 TROUBLESHOOTING AND REPAIR
CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued)
F-64
CALIBRATION SET-UP
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Load the Power Wave Manager Utility Software into the computer.
2. Use the Ethernet cable to connect the computer to the Power Wave ® S500.
3. Connect a resistive load bank to the output studs.
4. Energize the Power Wave ® S500.
5. Launch the Power Wave Manager Utility and establish communication with the Power Wave ®
S500 (Refer to the Software Documentation to determine proper connection).
6. Click on the “Calibration” Tab. A screen similar to Figure F.24
should appear and you are ready to begin the calibration check.
NOTE: The Calibration Screen may look slightly different depending on the
Software version.
Calibration can only be done under
“Static Load” conditions. Do not attempt to calibrate while welding.
NOTE: Incorrect calibration can and will affect welding performance. It is strongly recommended to use the screen to run and save a “Snapshot” before making any calibration adjustments. This will allow returning to original settings if necessary. (Refer to the
Software Documentation for instructions on using the Snapshot feature).
CALIBRATION PROCEDURE:
1. Once in the “Calibration” screen, make sure that the machine output is OFF (light is BLACK) and connect a resistive load bank to the output studs.
2. Set the load bank for 300 Amps.
3. On the Calibration screen, select the 300 Amps
Current Set Point.
NOTE: If the meters on the load bank are not certified, connect calibrated and traceable meters to the machine output. (See
Materials Needed at the beginning of this
Section).
WARNING
The Output Studs of the Machine will be
Electrically “HOT” during Steps 4 thru 7.
-------------------------------------------------------------------
4. Click on the “Turn Output ON” button. The
BLACK light on the screen will flash RED indicating that the weld output is turned ON. See
Figure F.24.
5. Adjust the load bank to 300 Amps at approximately 32 Volts as read on the external calibrated meters.
6. Using the “Calibration Adjustment” buttons:
Adjust the current so that the external ammeter reads 300 Amps +/-2A. Adjust the voltage so that the “Output Voltage” display window reads the same as the external voltmeter +/-.3 volts.
7. Click on the “Turn Output OFF” button.
Calibration is complete. (Also check at 300
Amps + 50 Amps).
POWER WAVE ® S500
F-65 TROUBLESHOOTING AND REPAIR
CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued)
F-65
FIGURE F.24 – CALIBRATION SCREEN
POWER WAVE ® S500
F-66 NOTES F-66
POWER WAVE ® S500
F-67 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the PFC Control
Board.
MATERIALS NEEDED
3/8” Wrench
Wiring Diagram
F-67
POWER WAVE ® S500
F-68 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.25 – PFC CONTROL BOARD LOCATION
F-68
FRONT PANEL
ASSEMBLY
PFC CONTROL
BOARD
PFC BOARD
MOUNTING PANEL
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Perform the Case Cover Removal and DC
Link Capacitor Discharge Procedure .
Remove the right and left side case covers.
3. Locate the PFC Control Board. See Figure
F.25.
4. Label and remove plugs J20, J21, J22, J23A,
J23B, J24, J25 and J26. See Figure F.26
. See
Wiring Diagram.
5. Using a 3/8” wrench, remove the four nuts securing the PFC Control Board to the PFC board mounting panel. See Figure F.25.
6. Carefully remove the PFC Control Board from the mounting studs. Cut any cable ties that may inhibit the removal.
POWER WAVE ® S500
F-69 TROUBLESHOOTING AND REPAIR
PFC CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.26 – PFC CONTROL BOARD PLUG LOCATIONS
J23A J23B
J22
J21
J20
J23A
Q9
X1
Q2
C13
X13
C16
D5 D6
X2
C1
X8
C14
X14
FTP26
FTP15
X21
Q3 D49
OCI1
D26
FTP21
X31
X26
X27
FTP17
DZ19
X9
DZ20
FTP29
OCI5
D7
X3
C4
FTP9
D9
C5
D10
X4
T1
C6
FTP7
D11
C7
FTP8
D12 X5
D18 D19
X6
J23B
D20
OCI2
D27
X18 X19 X17 X16
D28
R257
OCI3
D29
Y2
J2
1
FTP5
LED2
LED5
1
J1
FTP6
FTP38
X10
FTP12
FTP11
FTP2
D36 D33 D35 D38 D34 D37
C29
D56
D57
C30
FTP40
D62
X24
LED1
Q8
OCI4
X20
X25
D51
C10
X12
Q1
X7
Q10
C20
C31
X29 X30 Q7
D61
C32
D67 D66
C33
Q6
C34
G6860-1
D69
R212
FTP3
MOUNTING STUDS
AND NUTS
(4 PLACES)
REPLACEMENT PROCEDURE
1. Place the new PFC Control Board onto the mounting studs.
2. Using a 3/8” wrench, attach the four nuts securing the PFC Control Board to the PFC board mounting panel.
3. Connect plugs J20, J21, J22, J23A, J23B, J24,
J25 and J26 to the PFC Control Board. See
Wiring Diagram.
4. Attach any cable ties that may have been removed.
5. Perform the Case Cover Replacement
Procedure .
J24
J25
J26
F-69
POWER WAVE ® S500
F-70 NOTES F-70
POWER WAVE ® S500
F-71 TROUBLESHOOTING AND REPAIR
115 VOLT SUPPLY BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the 115 Volt
Supply Board.
MATERIALS NEEDED
3/8” Wrench
Wiring Diagram
F-71
POWER WAVE ® S500
F-72 TROUBLESHOOTING AND REPAIR
115 VOLT SUPPLY BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.27 – 115 VOLT SUPPLY BOARD LOCATION
F-72
115 VOLT
SUPPLY BOARD
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Perform the Case Cover Removal and DC
Link Capacitor Discharge Procedure .
Remove the right side case cover.
3. Locate the 115 Volt Supply Board. See Figure
F.27.
4. Label and remove plugs J82 and J83. It is not necessary to remove plug J81. See Figure
F.28
. See Wiring Diagram.
5. Label and disconnect the leads connected to tab terminals B5 and B6. See Figure F.28
.
See Wiring Diagram.
6. Using a 3/8” nutdriver, remove the four nuts securing the 115 Volt Supply Board to the front divider panel. See Figure F.28
.
7. Carefully remove the 115 Volt Supply Board from the mounting studs. Cut any cable ties that may inhibit the removal.
POWER WAVE ® S500
F-73 TROUBLESHOOTING AND REPAIR
115 VOLT SUPPLY BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.28 – 115 VOLT SUPPLY BOARD LEAD LOCATIONS
F-73
J83
J82
J83
J82
J81
LED 2
LED 1
LED 3
B5
B6
NUTS
(4 PLACES)
J81
B5
REPLACEMENT PROCEDURE
1. Place the new 115 Volt Supply Board onto the mounting studs.
2. Using a 3/8” nutdriver, attach the four nuts securing the 115 Volt Supply Board to the front divider panel.
3. Attach plugs J82 and J83 to the 115 Volt Supply
Board. See Wiring Diagram.
4. Attach the leads previously removed to tab terminals B5 and B6. See Wiring Diagram.
5. Replace any cable ties that may have been removed.
6. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
B6
F-74 NOTES F-74
POWER WAVE ® S500
F-75 TROUBLESHOOTING AND REPAIR
40 VOLT DC BUS BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the 40 Volt DC
Bus Board.
MATERIALS NEEDED
3/8” Wrench
Wiring Diagram
F-75
POWER WAVE ® S500
F-76 TROUBLESHOOTING AND REPAIR
40 VOLT DC BUS BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.29 – 40 VOLT DC BUS BOARD LOCATION
F-76
40 VOLT DC
BUS BOARD
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Perform the Case Cover Removal and DC
Link Capacitor Discharge Procedure .
Remove the right side case cover.
3. Locate the 40 Volt DC Bus Board. See Figure
F.29.
4. Locate and remove plugs J46 and J47. See
Figure F.30
. See Wiring Diagram.
5. Using a 3/8” nutdriver, remove the four nuts securing the 40 Volt DC Bus Board to the front divider panel. See Figure F.30
.
6. Carefully remove the 40 Volt DC Bus Board from the mounting studs.
POWER WAVE ® S500
F-77 TROUBLESHOOTING AND REPAIR
40 VOLT DC BUS BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.30 – 40 VOLT DC BUS BOARD MOUNTING NUT AND LEAD LOCATIONS
F-77
NUTS
(4 PLACES)
J47
LED 1
LED1
J46
NUTS
(4 PLACES)
L15732-1
REPLACEMENT PROCEDURE
1. Place the new 40 Volt DC Bus Board onto the mounting studs.
2. Using a 3/8” nutdriver, attach the four nuts securing the 40 Volt DC Bus Board to the front divider panel.
3. Connect plugs J46 and J47 to the 40 Volt DC
Bus Board. See Wiring Diagram.
4. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
F-78 NOTES F-78
POWER WAVE ® S500
F-79 TROUBLESHOOTING AND REPAIR
LINE SWITCH
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Line Switch.
MATERIALS NEEDED
5/16” Nutdriver
Wiring Diagram
Electrical Tape
Slotted Screwdriver
F-79
POWER WAVE ® S500
F-80 TROUBLESHOOTING AND REPAIR
LINE SWITCH
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.31 – LINE SWITCH LOCATION
F-80
LINE SWITCH
LINE SWITCH
COVER
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Perform the Case Cover Removal and DC
Link Capacitor Discharge Procedure .
Remove the right side case cover.
3. Locate the Line Switch. See Figure F.31.
4. Using a 5/16” nutdriver, remove the two screws securing the Line Switch to the front panel. See
Figure F.31.
5. Carefully remove the Line Switch from the front panel and slide it to the right side to gain access to the leads. Remove the electrical tape and take note of the line switch cover for reassembly.
6. Using a slotted screwdriver, label and remove leads L4A, L5A and L6A from the Line Switch.
See the Wiring Diagram.
7. Using a slotted screwdriver, label and remove leads L4, L5 and L6 from the Line Switch. Take note of the MOV assembly for reassembly. See the Wiring Diagram.
8. Remove the Line Switch.
POWER WAVE ® S500
F-81 TROUBLESHOOTING AND REPAIR
LINE SWITCH
REMOVAL AND REPLACEMENT PROCEDURE (continued)
REPLACEMENT PROCEDURE
1. Attach and securely tighten leads L4, L5 and L6 into the new Line Switch. Make sure the MOV assembly is also attached securely. See the
Wiring Diagram.
2. Attach and securely tighten leads L4A, L5A and
L6A into the new Line Switch. See the Wiring
Diagram.
3. Replace the electrical tape with new tape as required.
4. Using a 5/16” nutdriver and the two mounting screws previously removed, mount the new
Line Switch and switch cover onto the front panel.
5. Make sure all leads are cleared and the Line
Switch cover is in place.
6. Perform the Case Cover Replacement
Procedure .
F-81
POWER WAVE ® S500
F-82 NOTES F-82
POWER WAVE ® S500
F-83 TROUBLESHOOTING AND REPAIR
INPUT BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Input Board.
MATERIALS NEEDED
3/8” Nutdriver
7/16” Wrench
Cable Ties
Wiring Diagram
F-83
POWER WAVE ® S500
F-84 TROUBLESHOOTING AND REPAIR
INPUT BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.32 – INPUT BOARD LOCATION
F-84
INPUT
BOARD
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input voltage from the Power
Wave ® S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Input Board. See Figure F.32.
4. Carefully remove the input board cover. Cut the three cable ties holding the input board cover in place.
5. Label and remove plug J1 from the Input Board.
See Figure F.33
. See Wiring Diagram.
6. Using a 7/16” wrench, label and remove leads
B1, B2 and B3 from the Input Board. See
Figure F.33
. See Wiring Diagram.
7. Using a 7/16” wrench, label and remove leads
B4 and B5 from the Input Board. See Figure
F.33
. See Wiring Diagram.
8. Using a 3/8” nutdriver, remove the four nuts securing the Input Board to the mounting posts.
See Figure F.33
.
POWER WAVE ® S500
F-85 TROUBLESHOOTING AND REPAIR
INPUT BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.33 – INPUT BOARD LEAD LOCATIONS
J1
R6 R3 R7
J1
F-85
CR1
B3
MOUNTING
NUTS
(4)
B4
B2
D6
CR2
B1
B5
REPLACEMENT PROCEDURE
1. Position the new Input Board and heat sink assembly onto the four mounting posts.
2. Using a 3/8” nutdriver, attach the four nuts securing the Input Board to the mounting posts.
3. Connect Plug J1 into the new Input Board.
4. Connect leads B4 and B5 onto the new Input
Board. Torque to 50 to 60 Inch Pounds.
5. Using a 7/16” wrench, attach leads B1, B2 and
B3 to the new Input Board. Torque to 50 to 60
Inch Pounds.
6. Replace the input board cover using three new cable ties.
7. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
F-86 NOTES F-86
POWER WAVE ® S500
F-87 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Digital
Control Board.
MATERIALS NEEDED
3/8” Wrench
Wiring Diagram
F-87
POWER WAVE ® S500
F-88 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.34 – DIGITAL CONTROL BOARD LOCATION
F-88
DIGITAL CONTROL
BOARD
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Perform the Case Cover Removal and DC
Link Capacitor Discharge Procedure .
3. Carefully lift up the top case cover.
4. Locate the Digital Control Board. See Figure
F.34.
5. Label and remove plugs J5, J6, J7, J8, J9, J12,
J11 and J14. See Figure F.35
. See Wiring
Diagram.
6. Label and remove the Ethernet cable from the board. See Wiring Diagram.
7. Using a 3/8” nutdriver, remove the four nuts securing the Digital Control Board to the top case cover. See Figure F.35
.
8. Carefully remove the Digital Control Board from the mounting studs.
POWER WAVE ® S500
F-89 TROUBLESHOOTING AND REPAIR
DIGITAL CONTROL BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.35 – DIGITAL CONTROL BOARD LEAD LOCATIONS
F-89
J12
MOUNTING STUDS
AND NUTS
(4)
J5 J6 J7 J8 J9
D1 D3
Q3 Q6
J8
J5 J6
J7 J9
D4 D6
D2 D5
D8
Q1
X94 X96 X95 X97
X4
X99
X5
X93 X98
X13
Q24
Q25
Q11
X18
X19
X75
S3 S1
Q10
X33 Q16
BT1
X83 X82 X29
Y1
X28
X81
Y2
X46
X53
R12
R15
R24
DZ31
DZ32
O
N
S2 OCI5 OCI6
J11
X67
X57
D35
J13
X48
L7
X49
Y3
X62
C255
Q20
OCI10 OCI9
C15
X64
X1
X59
Q18
OCI7 OCI8
Q19
D38 D39 D40 D41
X68
C11
J2 J4
X92
X50
C12
C18
D42
X34
R510
R6
R21
X100
X20
X35
X51
D54
D16
X9
D17
X10
X22
C8
Q31 X38
X11
C6
Q14
X41 X25 X36 X85 X12
L14
FTP1
LED9
T2
OCI12
C9
C10 CT1
X63
D30
C14
X70
C13
C19 C22
Q22
C20
C21
C292
X72
L11
FTP3
Q23
L12
X73 X74
D19
D22
X26
X24
X21
J11 J14
MOUNTING STUDS
AND NUTS
(4)
REPLACEMENT PROCEDURE
1. Place the new Digital Control Board onto the mounting studs.
2. Using a 3/8” nutdriver, attach the four nuts securing the Digital Control Board to the top case cover.
3. Connect the Ethernet cable into the Digital
Control Board.
4. Connect plugs J5, J6, J7, J8, J9, J12, J11 and
J14 previously removed. See Wiring Diagram.
5. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
F-90 NOTES F-90
POWER WAVE ® S500
F-91 TROUBLESHOOTING AND REPAIR
FAN
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Fan
Assembly.
MATERIALS NEEDED
5/16” Nutdriver
Screwdriver
Wiring Diagram
F-91
POWER WAVE ® S500
F-92 TROUBLESHOOTING AND REPAIR
FAN
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.36 – FAN ASSEMBLY COMPONENT LOCATIONS
F-92
BRICKWORK PANEL
MOUNTING SCREWS
(6)
FAN ASSEMBLY
MOUNTING SCREWS
(4 PER ASSEMBLY)
BRICKWORK
PANEL
FAN ASSEMBLIES
(2)
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove input power to the Power Wave ® machine.
S500
2. Using a 5/16” nutdriver, remove the six screws from the brickwork panel located at the rear of the machine to gain access to the Fan
Assembly. See Figure F.36.
3. Using a screwdriver, remove the four machine screws and associated lockwashers and flatwashers from the Fan Assembly to be replaced.
See Figure F.36.
4. Carefully remove the Fan Assembly from the machine and disconnect the appropriate lead connection plug. (J55 or J56). See the Wiring
Diagram. Cut any necessary cable ties.
POWER WAVE ® S500
F-93 TROUBLESHOOTING AND REPAIR
FAN
REMOVAL AND REPLACEMENT PROCEDURE (continued)
REPLACEMENT PROCEDURE
1. Place the new Fan Assembly into position in the machine.
2. Connect the lead connection plug (J55 or J56).
See the Wiring Diagram.
3. Replace any cable ties previously removed.
4. Using a screwdriver, attach the four machine screws, associated lockwashers and flatwashers to the Fan Assembly.
5. Make sure the fan spins freely without any obstruction.
6. Using a 5/16” nutdriver, attach the six screws securing the brickwork panel located at the rear of the machine.
F-93
POWER WAVE ® S500
F-94 NOTES F-94
POWER WAVE ® S500
F-95 TROUBLESHOOTING AND REPAIR
POWER CONVERSION BOARD ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Power
Conversion Board Assembly.
MATERIALS NEEDED
3/8” Nutdriver
7/16” Wrench
5/16” Nutdriver
Wiring Diagram
F-95
POWER WAVE ® S500
F-96 TROUBLESHOOTING AND REPAIR
POWER CONVERSION BOARD ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.37 – POWER CONVERSION BOARD ASSEMBLY LOCATION
F-96
AIR BAFFLE
POWER CONVERSION
BOARD ASSEMBLY
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input voltage from the Power
Wave ® S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Power Conversion Board Assembly.
See Figure F.37.
4. Using a 5/16” and 3/8” nutdrivers, remove the air baffle. See Figure F.37.
5. Label and remove plugs J32, J33, J34, J35, J36 and J37 from the Power Conversion Board.
See Figure F.38
. See Wiring Diagram.
6. Using a 7/16” wrench, label and remove the heavy lead B2 from terminal B56. See Figure
F.38
. See Wiring Diagram. Save the bolt and washer for reassembly. Note chokes ʼ lead placement on terminal B56.
7. Using a 7/16” wrench, label and remove the heavy leads 901C and 901A from the heat sink terminal. Save the bolt, washers and nut for reassembly. See Figure F.38
. See Wiring
Diagram.
POWER WAVE ® S500
F-97 TROUBLESHOOTING AND REPAIR
POWER CONVERSION BOARD ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.38 – POWER CONVERSION BOARD ASSEMBLY LEAD LOCATIONS
J32 J33
MOUNTING
SCREWS
(5 PLACES)
B13
B
29
J32 J33 B28
L3
R70
LED4
J37
C19
DZ26
R54
R55
OCI1
D1
R52
LED5
D15
R31
DZ24
C11
R1
R3
T3
DZ3
LED3
C10
DZ23
R34
R35
T4
R61
D5
DZ4
R27
R2
FTP3
B16
C38
LEAD B5
F-97
TO TOP
INPUT CHOKE
B
2
B5
X1
LEAD B4
C21
C18 C40
LEAD B2
B8
T5
C17 B8
L2
C33
B56
B56
L4 B7
R81
B6 X2
B7
D11
R80
R79
D10
B18
R78
LEAD 901C
R9
R68
C20
C36
C2
FTP1
R28
DZ19
R37
TO BOTTOM
INPUT CHOKE
HEAT SINK
TERMINAL
B4
C39
LEAD 901A
J36
B9
J35
C7
T2
R65
D9
DZ13
DZ7
LED1
T1
C5
R41
R24
R23
J34
DZ14
R42
DZ8
C3
R21
R22
C8
D6
DZ6
DZ16
R25
R26
T6
C34
B6
MOUNTING
STUD WITH
NUT AND
WASHER
(1 PLACE)
J35 J34
8. Using a 7/16” wrench, label and remove the top choke leads from terminals B13 and B8. Save the bolts and lock washers for reassembly. See
Figure F.38. See Wiring Diagram.
9. Using a 7/16” wrench, label and remove the bottom choke leads from terminals B6 and B7.
Save the bolts and lock washers for reassembly. See Figure F.38. See Wiring Diagram.
10. Using a 7/16” wrench, label and remove the leads B4 and B5 from the buss bars. Save the bolts, lock washers and nuts for reassembly.
See Figure F.38. See Wiring Diagram.
11. Using a 5/16” nutdriver, remove the five screws securing the Power Conversion Board
Assembly to the frame of the machine. See
Figure F.38.
12. Using a 3/8” nutdriver, remove the nut and washer from the mounting post Lower left hand corner. See Figure F.38.
13. Clear all leads and carefully remove the Power
Conversion Power Board Assembly with heat sink from the machine.
POWER WAVE ® S500
F-98 TROUBLESHOOTING AND REPAIR
POWER CONVERSION BOARD ASSEMBLY
REMOVAL AND REPLACEMENT PROCEDURE (continued)
REPLACEMENT PROCEDURE
1. Position the new Power Conversion Board
Assembly onto the mounting post.
NOTE: The top of the Power Conversion Board
Assembly will have to be positioned into place first.
2. Using a nut and washer previously removed,
Secure the new Power Conversion Board
Assembly onto the mounting post. See Figure
F.38
.
3. Using a 5/6” nutdriver, replace the five mounting screws and washers previously removed.
4. Attach leads B4 and B5 onto their respective bus bars. See Figure F.38
. See Wiring
Diagram. Torque the bolts to between 50 and
60 inch pounds.
5. Attach the bottom choke leads to terminals B6 and B7. See Figure F.38
. See Wiring Diagram.
Torque the bolts to between 50 and 60 inch pounds.
6. Attach the top choke leads to terminals B13 and
B8. See Figure F.38
. See Wiring Diagram.
Torque the bolts to between 50 and 60 inch pounds.
7. Attach the two heavy leads 901C and 901A to the heat sink terminal. See Figure F.38
. See
Wiring Diagram. Torque the bolts to between
50 and 60 inch pounds.
8. Attach the heavy lead B2 to terminal B56. See
Figure F.38
. See Wiring Diagram. Torque the bolts to between 50 and 60 inch pounds. Note chokes ʼ lead placement.
9. Attach plugs J32, J33, J34, J35, J36 and J37.
See Figure F.38
. See Wiring Diagram.
10. Attach the air baffle. See Figure F.37
.
11. Clear and position all leads.
12. Perform the Case Cover Replacement
Procedure .
F-98
POWER WAVE ® S500
F-99 TROUBLESHOOTING AND REPAIR
CHOPPER BOARD
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the Chopper
Board.
MATERIALS NEEDED
3/8” Nutdriver
7/16” Wrench
Cable Ties
Wiring Diagram
F-99
POWER WAVE ® S500
F-100 TROUBLESHOOTING AND REPAIR
CHOPPER BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.39 – CHOPPER BOARD LOCATION
F-100
MULTI-PHASE
CHOPPER BOARD
REMOVAL PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Remove the input voltage from the Power
Wave ® S500 machine.
2. Perform the Case Cover Removal and
Capacitor Discharge Procedure .
3. Locate the Chopper Board. See Figure F.39.
4. Locate and remove plugs J41 and J42 from the
Chopper Board. See Figure F.40
. See Wiring
Diagram.
5. Using a 7/16” wrench, label and remove leads
BL1, BL2, BL3, BL4, BL5 and BL6 from the
Chopper Board. Save the bolts and lock washers for reassembly. See Figure F.40
. See
Wiring Diagram.
6. Using a 7/16” wrench, label and remove leads
901, 901C and 206A from terminal B1. Save the bolts and lock washers for reassembly. See
Figure F.40
. See Wiring Diagram.
POWER WAVE ® S500
F-101 TROUBLESHOOTING AND REPAIR
CHOPPER BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.40 – CHOPPER BOARD LEAD LOCATIONS
BL6
BL5
R75
D115
R77
R76
R79 R78
4 R7
R3
R1
R2
R29
C26
8 DZ1
5 D1
L9
L1
R34
C15
C16
R47
BL4
D112
R68
R69
R6
BL3
R71
0 R7
R5
X19
C63
C74
D120
BL2
BL1
R73 R72
R4
J41
LEAD 410
LEAD 410
J42
F-101
B2 3/8 INCH
MOUNTING NUTS
(4 PLACES TOP
AND BOTTOM)
7. Using a 7/16” wrench, label and remove leads
B2 and 207 from terminal B2. Save the bolts and lock washers for reassembly. See Figure
F.40. See Wiring Diagram.
8. Label and disconnect the two thermostat leads
409 and 410. These leads can be disconnected at the two in-line push-on connectors. See
Figure F.40. See Wiring Diagram.
B1
9. Using a 3/8” nutdriver, remove the four nuts securing the Chopper Board Assembly to the mounting posts. See Figure F.40.
10. Carefully remove the Chopper Board Assembly
(with heat sink) from the machine by clearing all leads and lifting the lower portion up and out first.
POWER WAVE ® S500
F-102 TROUBLESHOOTING AND REPAIR
CHOPPER BOARD
REMOVAL AND REPLACEMENT PROCEDURE (continued)
F-102
REPLACEMENT PROCEDURE
1. Position the new Chopper Board and heat sink assembly onto the four mounting posts.
NOTE: The bottom of the Chopper Board
Assembly will have to be positioned into place first.
2. Using the four nuts previously removed, secure the new Chopper Board onto the mounting posts.
3. Connect Plugs J41 and J42 into the new
Chopper Board. See Wiring Diagram.
4. Connect the thermostat leads 409 and 410.
See Wiring Diagram.
5. Connect leads 901, 901C and 206A to terminal
B1. Torque the bolts to between 50 to 60 inch pounds. See the Wiring Diagram.
6. Connect leads B2 and 207 to terminal B2.
Torque the bolts to between 50 to 60 inch pounds. See the Wiring Diagram.
7. Connect the six output choke leads previously removed from terminals BL1, BL2, BL3, BL4,
BL5 and BL6. Torque the bolts to between 50 to 60 inch pounds. See the Wiring Diagram.
8. Perform the Case Cover Replacement
Procedure .
POWER WAVE ® S500
F-103 TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR PROCEDURE
WARNING
Service and repair should be performed only by Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in testing the Power Wave ® repair or replacement of a part or PC board.
S500 output after the
MATERIALS NEEDED
Power Wave Manager Utilities Software
Laptop or other Suitable Computer
Ethernet Cross Connect Cable (LE Co. #M19969-7)
Resistive Load Bank
Two (2) Welding Cables - 20ft. -4/0
Calibrated Ammeter and Voltmeter
F-103
POWER WAVE ® S500
F-104 TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR PROCEDURE (continued)
F-104
PROCEDURE
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or electrodes with your skin or wet clothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------
1. Be certain that the machine is properly connected for the input voltage being applied.
2. Turn the Power Switch ON and see that it goes through the Start-up routine and the Status
Light is steady Green.
3. Turn the Power Switch OFF and connect a resistive load across the Output Studs and a computer to the Ethernet. Perform the Current and
Voltage Calibration Procedure to be sure that the machine will produce proper weld output.
POWER WAVE ® S500
G-1
TABLE OF CONTENTS - DIAGRAM SECTION
G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (G7188) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Schematic – (G7189) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3 thru G-5
PC Board Assembly – Control PC Board (G6682-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6 thru G-8
PC Board Assembly – PFC Control Board (G6860-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9, G-10
* NOTE:
Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered and are therefore considered to be unserviceable. Assembly drawings of these boards are provided for reference only.
POWER WAVE ® S500
G-2
WIRING DIAGRAM - (G7188)
ELECTRICAL DIAGRAMS
POWER WAVE S500
L3
TO
SUPPLY
L2
L1
TB
U
L3
V
L2
W
L1
414
413
412
411
7
2
6
1
J61
115 VAC
INVE RTER PCB
(ASSEMBLY G6571)
B5
B6
317
318
OPTIONAL
DEVICENET
33A
33
34
32
32A
GND5
115V
J15
DIGITAL CONTROL BOARD
G6682
J3
6
7
8
9
10
1
2
3
4
5
65A
66
1
2
3
4
J46
DC BUS
BOARD
L15732
J47
1
2
3
4
5
6
7
8
51A
52
51
52A
ETHERNET
CONNECTOR
RJ 45
TYPE
ETHERNET
CABLE
67C 67D
67E
CB2
10A
65A
65
FAN
R / Y
B
N / U
R / Y
FAN
B
N / U
J56
1
3
2
353B
351B
359B
J55
1
3
2
353C
351C
359C
J53
4
8
2
1
5
6
353
351
359
353A
351A
359A
553A
GAS
SOLENOID
(OPTIONAL)
554A
553
554
901A
/
901C
351A
66
351
359A
359
353A
65
353
350
355
HEAT
SINK
3
2
1
7
6
5
4
10
9
8
S3 ARCLINK
RECEPTACLE
ARCLINK A
ARCLINK + B
ELECTRODE
SENSE
C
+40VDC D
0 VDC E
.0047uF
53A
53B
54A
54B
67A
67B
52A
52B
51A
51B
L3
L4
A
B
DIFF_1 HIGH C
DIFF_1 LOW
DIFF_2 HIGH
DIFF_2 LOW
D
E
F
S5
SYNC/TANDEM
CONNECTOR
1
+24 VDC INPUT 2
+24 VDC COMMON 3
DNET CAN_H 4
DNET CAN_L 5
894
893
892
891
G
B/G
R
B/R
L7
S4
DEVICENET
CONNECTOR
(OPTIONAL)
L5
L6
B2 B56
B23
51A
52A
67A
54A
53A
51B
52B
67B
54B
53B
4
5
6
7
8
1
2
3
9
10
J55
51A
52A
67
54A
53A
51C
52C
67C
54C
53C
CHOKES
T12218-37
318
317
3
2
1
8
7
6
5
4
J36
G
B/G
R
B/R
1
2
3
4
J50
357
354
352
349
B20
POWER BOARD
G7150
GROUND BOND CIRCUIT
BASE
GND1 VERTICAL PANEL
GND2 CASEBACK
GND3 CASEFRONT
G
TO EARTH GROUND PER THE
NATIONAL ELECTRIC CODE
B13
B8
B7
B6
B18
B28
B17
B29
B2
901C / 901
B1
CHOPPERCONTROL
BOARD G6786
8
7
6
5
4
3
2
1
348
347
346
345
344
343
342
341
B2
INPUT
CHOKES
L16139
5.0 MF
CAP.
B4
B4
B2
B1
B5
B5
5A
6A
1
2
3
4
216
217
215
218
OUTPUT
CHOKE
L13270-4
BL1
BL2
A
A2
BL3
BL4
BL5
BL6
A3
A4
A5
A6
CHOPPER BOARD
G7245
.01 MF
CASE BACK
.01 MF
PRESENT ON MACHINES
BUILT AFTER 4/19/2013
B3
4A
INPUT BOARD
M22489-2
J1
10
9
8
5
4
7
6
3
2
1
362
366
367
369
901A
/
901
206A
207
200
OHM
100 W
316A
314A
336A
337A
331A
328A
315A
313A
332A
333A
335A
402
403
356
358
6
5
4
3
2
1
12
11
10
9
16
15
14
13
2
1
4
3
8
7
6
5
54
53
4
3
2
1
J23A
J22
J20
PFC CONTROL BOARD
G6860
J26
J25
214
211
213
212
218
215
217
216
CURRENT
TRANSDUCERS
4
3
2
1
4
3
2
1
LEM
LEM
+
+
6
5
4
8
7
12
11
10
9
3
2
1
4
3
2
1
6
5
361
366
362
326A
368
367
326B
369
GENERAL INFORMATION
ELECTRI CAL SYMBOLS PER E1537.
CAVITY NUMBER ING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)
LEAD COLOR CODING
B - BLACK
R RED
N- BROWN
V - VIOLET
G - GREEN
J10A1,
J10B1,
J811,
J2
1
2
J2, J5, J11,
J31, J46,
J51, J111,
J82, J81
1
3
J8, J24, J28,
J29, J43, J47,
J63, J84
1
5
4
8
2
4
N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
ALIGNS WITH WHITE LEAD OF LED SOCKET.
1
J12, J23,
J25, J42
6
6
12
J9, J13, J16,
J26, J27, J62,
J112, J83, J1
J3, J4,
J45, J61
J86
J6, J7,
J41, J85
J87
1
9
1
6
1
4
3
6
5
10
8
16
G
M
H
J
A
F
E
L
D
B
K
C
S1
1
2
4
3
S18657 (INSERTION END)
S2
E
D
A
C
B
S
1 2 1
7 3 S L D R N G
E D
S3
2
1
3
4
5
S4
F
A
B
E
D C
S12021-79 (INSERTION SIDE)
S5
67E
21
1
2
3
4
S2
VOLTAGE
SENSE
RECEPTACLE
5
6
INPUT
SWITCH
4
L1 T1
L2 T2
L3 T3
4A
5A
6A
OPTIONAL
KIT
K3001
USER
INTERFACE PCB
(ASSEMBLY G6554)
J31
J114
REMOTE CONTROL PCB
(ASSEMBLY G6948)
J111
J112
J115
3
4
5
1
2
8
9
6
7
10
77A
200A
4A
76A
75A
2A
51K
52K
53K
54K
8
9
6
7
10
J111
3
4
5
1
2
77
200
4
76
75
2
51F
52F
53F
54F
L2
377
378
376
375
4
3
2
1
J51
L1
B
THERMAL LED
W
W B
CONTROL BD STATUS
RED/GREEN LED
76
77
200
2
4
53F
S1
REMOTE
AMPTROLS
ARC LINK
CONNECTOR
A
54F
75
B
C
D
E
F
G
51F
52F K
L
H
J
M
208
100
OHM
100 W
209
L5
206
901A / 901
901B
M20305-1
903B
WORK
L6
202
G7188 C
G-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
Power Wave ® S500
G-3
SCHEMATIC - (G7189 PG 1)
ELECTRICAL DIAGRAMS G-3
89 G71
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED INPUT P.C. BOARD AND ARC LINK RECEPTACLE GRAPHICS.
USED FOR PRODUCTION MONITORING,
DOWNLOADING SOFTWARE, OR
UPLOADING MACHINE INFORMATION
ETHERNET
CONNECTOR P50
MACHINE
THERMOSTAT
LOCATED ON
FRONT OF
CHOPPER
HEATSINK
RJ 45
TYPE
LOCATED
LEFT
REAR PANEL
DIGITAL CONTROL
P.C. BOARD
Schematic: G4799
Assembly: G6682
LOCATED ON UNDERSIDE
OF ROOF PANEL, REAR
3RD IN POWER UP SEQUENCE
ARCLINK
53A
54A
51
40VDC
52
1J21
2J21
3J21
4J21
53
54
RECTIFIED AC +
SOFT START RELAY
369
367
+15V
362
RECTIFIED AC POWER +
366
LED5
PFC CONTROL
P.C. BOARD
LOCATED ON BACK
OF CASE FRONT
2J20
1J20
REGULATES
PRIMARY
VOLTAGE
AND CONTROLS
DEVICE
SWITCHING
LED1
LED3
1J25
6J25
12J25
4J26
LED4
BLK/RED
RED
BLK/GRN
GRN
SYNC-TANDEM
CONNECTOR
LOCATED ON
LEFT CASE
BACK BOTTOM
F
E
D
C
S5
21
67
5J13
2J13
1J13
4J13
10J4
12J6
LEM COMMON
LEM FEEDBACK
-15VDC LEM SUPPLY
+15VDC LEM SUPPLY
894
893
892
891
LOCATED ON
CASE BACK, RIGHT
24 VDC
894
COMMON
893
DEVICENET CAN H
892
DEVICENET CAN L
891
S4
DEVICENET
CONNECTOR
(OPTIONAL)
2 +24 VDC
3 +24 GND
4 CAN_H
5 CAN _L
553
554
67 67E
LOCATED ON
CASE FRONT
LOWER RIGHT
67E 21
S2
VOLTAGESENSE
RECEPTACLE
AUTOREMOTE
SENSEUSE
P.81, P.82
16J23A
8J23A
14J23A
6J23A
12J23A
4J23A
11J23A
3J23A
7J24
3J24
1J24
5J24
10J23A
2J23A
9J23A
11J25
9J25
6J26
9J23B
1J23B
11J23B
3J23B
13J23B
5J23B
14J23B
6J23B
6J24
2J24
4J24
8J24
15J23B
7J23B
16J23B
5J25
SEE PAGE 2 FOR
BOARD LED HELP
VOLTAGE
FEEDBACK
TYPICAL FEEDBACK
4 VDC = 500 A
FOLDS BACK TO
375 A WITH A
SHORT CIRCUIT
3J7
4J7
8J7
7J7
553
20 OHM
12V PULL
6V HOLD
553A
554 554A
GAS SOLENOID
LOCATED ON
CASE BACK
LOWER LEFT
USER INTERFACE PCB
Schematic: G6735
Assembly: G6554
B1
250VAC
.0047uF
U.I. KIT
K3001
(OPTIONAL)
FAN
B
N OR U
R OR Y
FAN
334A
338A
331A
335A
328A
326A
336A
332A
337A
333A
308A
307A
316A
315A
314A
313A
368
361
336B
332B
337B
333B
308B
307B
334B
338B
331B
335B
328B
326B
316B
315B
314B
313B
R OR Y
B
N OR U
J56
1
3
2
353B
351B
359B
J55
1
3
2
353C
351C
359C
!!! HIGH VOLTAGE !!!
FLOATING VOLTAGE
POTENTIAL TO GROUND
MAIN BUCK DRIVE A+
MAIN BUCK DRIVE A-
AUX BUCK DRIVE A+
AUX BUCK DRIVE A-
MAIN BOOST DRIVE A+
MAIN BOOST DRIVE A-
AUX BOOST DRIVE A+
AUX BOOST DRIVE A-
FULL BRIDGE A+
FULL BRIDGE A-
CT A*
CT A
+15V A
-15V A
LEM A
THERMAL FAULT A
PRIMARY CAPACITOR VOLTAGE
COMMON
MAIN BUCK DRIVE B+
MAIN BUCK DRIVE B-
AUX BUCK DRIVE B+
AUX BUCK DRIVE B-
MAIN BOOST DRIVE B+
MAIN BOOST DRIVE B-
AUX BOOST DRIVE B+
AUX BOOST DRIVE B-
FULL BRIDGE B+
FULL BRIDGE B-
CT B*
CT B
+15V B
-15V B
LEM B
THERMAL FAULT B
338A
331A
335A
328A
326A
336A
332A
337A
333A
308A
307A
334A
J53
4
8
2
1
5
6
FAN SPEED VARIES BASED ON
TEMPERATURES OF BUCK/BOOST
MODULES. 5V PWM CONTROL SIGNAL.
ALL REAR INTAKE SIDE EXHAUST.
353
351
359
353A
351A
359A
FAN POS.
FAN NEG.
FAN SPEED CONTROL
FAN POS.
FAN NEG.
FAN SPEED CONTROL
5V
48 VDC FAN
316A
315A
314A
313A
368
361
336B
332B
337B
333B
308B
307B
334B
338B
331B
335B
328B
326B
316B
315B
314B
313B
6J32
3J32
1J32
4J32
15J33
7J33
5J33
12J33
8J33
16J33
11J33
4J33
6J33
14J33
13J33
3J33
1J33
10J33
11J34
12J34
9J34
1J34
6J34
14J34
10J34
2J34
13J34
4J34
5J34
3J34
1J35
4J35
6J35
3J35
LED5
48VDC
CHOPPER CONTROL BOARD
(SCHEMATIC G6785)
36 PIN IN LINE CONNECTOR
377 378
THERMAL
LED
376 375
STATUS
RED/GREEN
LED
J51
LOCATED
ON CASE
BACK TOP
CB2
10A
LOCATED ON
FRONT RIGHT
200 OHM 100 W
B7
LED4
LED3
POWER CONVERSION
ASSEMBLY
P.C. BOARD
Schematic: G6845
Assembly: G7150
LOCATED
LEFT REAR
B6 B8
LOCATED RIGHT SIDE
PANEL REAR TOP
207
218
LEM COMMON
215
LEM FEEDBACK
217
-15VDC LEM SUPPLY
216
+15VDC LEM SUPPLY
MULTI-PHASE
OUTPUT CHOKE
LEFT
CENTER
LED2
B56
BUS
BAR
B2
901C/901A
901C/901
200 VAC
50 KHZ
5J36
8J36
317
318
B28
B18
B17
B29
SWITCHBOARD P.C. BOARD LED LEGEND
LED1: BTM BUCK IGBT DRIVE
LED2: BTM BOOST IGBT DRIVE
LED3: TOP BUCK IGBT DRIVE
LED4: TOP BOOST IGBT DRIVE
LED5: +48V AUXILIARY
901/901A
B4
INPUT
P.C. BOARD
Schematic: M22488
Assembly: M22489-2
B5
LED1
PRESENT ON MACHINES
BUILT AFTER 4/19/2013
.01 MF
.01 MF
200-600
VDC RMS
B3
B2
B1
CASE
BACK
B13
6-PHASE CHOPPER
LOCATED ON
RIGHT PANEL
REAR BOTTOM
Schematic: G6869
Assembly: G7245
TYPICAL
FEEDBACK
4 VDC = 500 A
4J42
3J42
2J42
FOLDS BACK
TO 375 A WITH
A SHORT CIRCUIT
1J42
LED1
LED2
LED3
LED4
LED5
LED6
BL1
BL2
BL3
BL4
BL5
BL6
B2 B1
EACH PHASE CONNECTED
TO SECONDARY COMMON
INPUT
CHOKES
BACK
LEFT
MIDDLE
LOCATED ON
CASE FRONT
MIDDLE
206A
LOCATED ON
LOWER FRONT
RIGHT SIDE
65A
66
J46-1
J46-2
J46-3
J46-4
DC BUS
BOARD
Schematic: M19330
Assembly: L11832
LED1
+40VDC 4J47
COMMON 5J47
+40VDC 8J47
317
318
COMMON
(See page 2 for LED information)
115 VAC
INVERTER PCB
OPTIONAL
(ASSEMBLY G6571)
B5
B6
3J63
7J63
1J63
5J63
8J63
1J61
6J61
2J61
7J61
LOCATED ON
RIGHT SIDE PANEL
FRONT TOP
L4A
L5A
L4
L5
FRONT RIGHT
MIDDLE
L6A L6
LINE
SWITCH
1J47
411
412
413
414
32
32A
33
33A
GND5
V
W
52
51A
51
52A
TERMINAL BLOCK
U
CB1
10A
DROP RED WIRE
FOR 1 PHASE
LOCATED ON
VERTICAL DIVIDER
LOWER REAR LEFT
BASE
GND1 VERTICAL PANEL
GND2 CASEBACK
GND3 CASEFRONT
67E
34
115V
(Neutral Bonded)
LOCATED ON
REAR PANEL
RIGHT SIDE
R
W
B
G
374
373
372
371
370
379
53C
54C
67D
52C
51C
53C
53
54C
54
67C
67
52C
52
51C
51
10J55
5J55
9J55
4J55
8J55
3J55
7J55
2J55
6J55
1J55
J55
3J112
6J112
4J112
8J112
5J112
7J112
1J114
3J114
5J114
6J114
4J114
REMOTE CONTROL PCB
Schematic: G6947
Assembly: G6948
LOCATED ON
UNDERSIDE OF ROOF
PANEL, FRONT
10P55
5P55
9P55
4P55
8P55
3P55
7P55
2P55
6P55
1P55
P55
30 AMP PEAK SURGE (NOT WELDING)
40 AMP PEAK SURGE (WELDING)
RIGHT THERMOSTAT TURNS FANS
ON, LEFT THERMOSTAT CUTS OFF
115V IF FANS ARE STALLED
INPUT VOLTAGE RANGE
200VAC - 575VAC THREE PHASE
220VAC - 415VAC SINGLEPHASE
50 TO 60 HZ
9J111
10J111
7J111
8J111
2J111
5J111
4J111
1J111
6J111
3J111
L3
L4
L5
L6
67A
52B
52A
51B
51A
53B
53A
54B
54A
67B
.0047uF
CURRENT
FEEDBACK FOR
CHOPPER BD
MOUNTED
UNDERNEATH
OUTPUT CHOKE
53F
54F
ARCLINK -
ARCLINK +
51F
52F
200
0 VDC
+40VDC
ALPS
75
76
75
76
77
2
77
TRIGGER
4
TRIGGER
L1
L2
S3 ARCLINK
RECEPTACLE
A ARCLINK -
B
ARCLINK +
C
D +40VDC
E 0 VDC
LEM
100 OHM
100 W
LOCATED ON
OUTPUT CHOKE
ASSEMBLY
209
208
LOCATED ON
CASE BACK, RIGHT
903B
S1 REMOTE
AMPTROLS
ARCLINK
RECEPTACLE
53F A ARCLINK -
54F B ARCLINK +
75
76
77
200
2
4
C 75
D 76
E 77
F
ALPS
G TRIGGER
H
TRIGGER
51F J 0 VDC
52F K +40VDC
L NOT USED
M NOT USED
LOCATED ON
CASE FRONT
LEFT FRONT LOW
STUD
TERMINALS
USED ON
K2904-1.
TWECO USED
ON K2904-2
RIGHT FRONT LOW
MOUNTED ON
CASE FRONT
ABOVE
OUTPUT STUDS
WELD CURRENT
FEEDBACK
MOUNTED ON
FRONT OF
OUTPUT CHOKE
LEM
1k OHM 25 W
1k OHM 25 W
Schematic: S26517
Assembly: M20305
202
_
206
+
901B
PROPRIETARY & CONFIDENTIAL:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
CONTROL: CLEVELAND
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
DRAWN BY:
ENGINEER: sajones
LLUO
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING APPROVED: GWM
SCALE:
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
POWER WAVE S500
MACHINE SCHEMATIC
APPROVAL
DATE:
4/19/2013
PROJECT
NUMBER:
CRM46188-B
REFERENCE:
G6535-2
DOCUMENT
NUMBER:
G7189
DOCUMENT
REVISION:
C
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Power Wave ® S500
G-4
SCHEMATIC - (G7189 PG 2)
ELECTRICAL DIAGRAMS G-4
OUTPUT
89 G71
ENGINEERING CONTROLLED
MANUFACTURER:
No
CHANGE DETAIL: REVISED INPUT P.C. BOARD AND ARC LINK RECEPTACLE GRAPHICS.
CONTROL
P.C. BOARD
ARC
CURRENT
SENSE
ARC
VOLTAGE
SENSE
DIFF I/O
SIGNALS
CHOPPER
CONTROL
THERMOSTATS
COOLER
ENABLE
PRIMARY
SHUTDOWN
ERRORS
J5 J6
J3 J5
O
N
S3
J12
O
N
S1
J6
SI SYNC
TERMINATION
SI LINK
TERMINATION
BT1
BT1
RJ45 (ETHERNET)
LED 8
LED 7
J11
O
N
S2
J11
J15
ARCLINK
TERMINATION
J13
J13
J2
J2
J4
J4
J7
LED'S
FAN CONTROL
LED 9
J8 J9
ARCLINK
DEVICENET INPUT POWER
COOLER INTERFACE
Description of LED functions on Power Wave S500 For reference only
LOGIC
COMMUNICATION
WITH CONTROL BD
THERMAL
FAULTS
J62
J61
LED 1
115VAC INVERTER
P.C. BOARD
LED 3
J63
200 VAC 50 KHZ IN
115 VAC OUT
Description of LED functions on Power Wave S500
For reference only
LED #
1
2
3
G6571 115 VAC INVERTER P.C. BOARD
COLOR FUNCTION
RED
ERROR CODE (LED WILL FLASH ERROR) SEE TABLE BELOW FOR
DETAILS
GREEN RECEPTACLE OUTPUT IS ON (115 VAC)
GREEN INPUT POWER PRESENT. POWER SUPPLY ON
ERROR CODE
ERROR EXPLANATION
1
2
GROUND FAULT
THERMAL FAULT
5
6
3
4
15V CONTROL UNDERVOLTAGE
200V BUS UNDERVOLTAGE
OUTPUT OVER CURRENT
OUTPUT OVER VOLTAGE
+40 VDC BUS
P.C. BOARD
INDICATES OUTPUT
J47
LED1
L15732-1
J46
INPUT
A-SIDE BUCK-BOOST
DRIVES LEM FEEDBACK
LED 3
40/36V OUTPUT AND
FAULT SIGNAL TO
DIGITAL CONTROL BD
CAN AND
40V INPUT
LED 4
PFC CONTROL
P.C. BOARD
Q9
X1
Q2
C13
X13
C16
D5 D6
X2
C1
X8
C14
X14
X21 Q3
FTP14
FTP15
D49
OCI1
D26
X31
X26
J23A
D7
X3
OCI2
D27
Y2
J23B
X4
C4
D9
C5
D10
T1
C6
D11
C7
D12
X5
D18 D19 D20
X6
C10
X12
Q1
X7
Q10
C20
X18 X19 X17 X16
D28
R257
OCI3
D29
OCI4
J2
1
FTP5
LED2
LED5
OCI5
FTP12
FTP11
1 J1
FTP6
FTP24
FTP22
X24
X20
LED1
X25
X27
DZ19
DZ20
X9
D36 D33 D35 D38 D34 D37
C29
D56
D57
C30
Q8
C31
D62
X29 X30 Q7
D61
C32
D67 D66
C33
Q6
C34
G6860-1
D69
R212
FTP3
B-SIDE BUCK-BOOST
DRIVES LEM FEEDBACK
LED 2
LED 5
FULL BRIDGE DRIVES
CURRENT FEEDBACKS
LED 1
RELAY DRIVE, BUS VOLTAGE
FEEBACK, AC VOLTAGE FEEDBACK,
AND TEMPERATURE FEEDBACKS
POWER IN
Description of LED functions on Power Wave S500
For reference only
LED #
1
2
3
4
5
G6860-1 PFC CONTROL P.C. BOARD
COLOR FUNCTION
GREEN /
RED
STATUS LIGHT AND ERROR CODE (LED WILL FLASH ERROR) SEE
TABLE FOR DETAILS
RED
FAULT SIDE B
GREEN -15 VOLT PRESENT
GREEN +15 VOLT PRESENT
RED FAULT SIDE A
ERROR CODE
ERROR EXPLANATION
331
334
PEAK INPUT CURRENT LIMIT
START UP CURRENT CHECK FAILURE
335
336
337
338
START UP VOLTAGE CHECK FAILURE
THERMAL FAULT (NO FIRST STAGE FAN)
PRECHARGE TIMEOUT
INPUT POWER LIMIT
341
346
347
349
INPUT VOLTAGE DROPOUT
TRANSFORMER PRIMARY OVERCURRENT
AVERAGE INPUT CURRENT LIMIT
BUS UNDERVOLTAGE
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL AN GLES IS ± .5 OF A DEGREE
CONTROL: CLEVEL
DRAWN BY:
AND sajones
DO NOT SCALE THIS DRAWING
ENGINEER:
APPROVED:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
LLUO
GWM
SCALE:
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUI
SU
PMENT TYPE:
BJECT:
MATERIAL
DISPOSITION:
UF APPROVAL
DATE:
POWER WAVE S500
MACHINE SCHEMATIC
4/19/2013 PROJECT
NUMBER:
CRM46188-B
REFERENCE:
G6535-2
DOCUMENT
NUMBER:
G7189
DOCUMENT
REVISION:
C
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Power Wave ® S500
G-5
SCHEMATIC - (G7189 PG 3)
ELECTRICAL DIAGRAMS G-5
89 G71
TO SWITCHBOARD
ENGINEERING CONTROLLED
MANUFACTURER: No
CHANGE DETAIL: REVISED INPUT P.C. BOARD AND ARC LINK RECEPTACLE GRAPHICS.
INPUT BOARD
FROM CONTROL BOARD
PRIMARY HARNESS
R6 R3 R7
J1
CR1
CR2
LED 1
INDICATES INPUT
VOLTAGE IS PRESENT
3 STAGE INVERTER
SWITCHBOARD
P.C. BOARD
LEDS 1-6 ON DAUGHTER BOARD
SHOW EACH PHASE IS ACTIVE
TO MULTIPHASE CHOKE
D115
R77
R76
R79
R75
MULTIPHASE
CHOPPER
R3
R74
R78
R29
C26
DZ18
D15
L9
L1
R34
C15
C16
R47
R1
R2
D6
TO B2 ON
CHOPPER BOARD
HEATSINK THIS SIDE
SECONDARY POTENTIAL
TO CHOPPER BOARD
AND POSITIVE STUD
AC INPUT
LED 5
RUBBER
SLEEVES
ON BASE OF
CAPACITORS
LED 4
LED 3
C19
DZ26
R54
R55
OCI1
D1
R52
LED5
J32
B11
XXXX
40V AUX
USE
R70
D15
R31
DZ24
C11
J33
LED4
R1
R3
T3 DZ3
B28
LED3
T4
R61
D5
DZ4
C10
DZ23
R34
R35
B12
R27
R2
L3
FTP3
B13
X1
B29
B16
C38
B5
C21
C18
C40
B8
T5
C17
L2
C33
B56
L4
B7
R81
R79
D10
D11
R80
R78
B6
X2
B10
B18
R9
R68
C20
C36
B17
C2
FTP1
R28
DZ19
R37
B4
C39
B15 B9
115V AUX
USE
XXXX
C7
T2
R65
D9
DZ13
DZ7
T1
C5
R41
LED1
R24
R23
J35 J34
DZ14
R42
DZ8
D6
DZ6
DZ16
C3
R21
R22
C8
R25
R26
T6
C34
= MOLEX PIN 1
LED 1
LED 2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
TO TOP
INPUT CHOKE
INPUT CAPACITOR
BOTH HEATSINKS
THIS SIDE FLOATED
R71
R70
D112
R68
R69
R6
R73 R72
R5
R4
TO B56 ON POWER BOARD
TO POWER BOARD BUS BAR
AND POSITIVE STUD
X19
C63
C74
D120
LED 1
ON WHEN
15 VOLT PRESENT
TO SECONDARY
HARNESS
TO LOWER
LEM
TO BOTTOM
INPUT CHOKE
Description of LED functions on Power Wave S500
For reference only
LED #
1
2
3
4
5
G7150 SWITCHBOARD P.C. BOARD
COLOR FUNCTION
GREEN BTM BUCK IGBT DRIVE FUNCTIONING WHEN ON
GREEN BTM BOOST IGBT DRIVE FUNCTIONING WHEN ON
GREEN TOP BUCK IGBT DRIVE FUNCTIONING WHEN ON
GREEN TOP BOOST IGBT DRIVE FUNCTIONING WHEN ON
GREEN 48 VDC AUXILIARY POWER FUNCTIONING WHEN ON
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
DO NOT SCALE THIS DRAWING
CONTROL: CLEVELAND
DRAWN BY:
ENGINEER:
APPROVED:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
sajones
LLUO
GWM
SCALE:
NONE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
POWER WAVE S500
MACHINE SCHEMATIC
4/19/2013
PROJECT
NUMBER:
CRM46188-B
REFERENCE:
G6535-2
DOCUMENT
NUMBER:
G7189
DOCUMENT
REVISION:
C
Power Wave ® S500
G-6
CONTROL PC BOARD ASSEMBLY (G6682-1 PG 1)
-1 82 G66
ENGINEERING CONTROLLED
MANUFACTURER: Yes
CHANGE DETAIL: REVISED ITEM 9 PART NUMBER
N.E.9
.74
N.E.8
7
N.A.1
N.E.2, N.G.3
N.A.6
N.A.5
11 12
N.E.4
N.E.2, N.G.3
N.E.1
3
ELECTRICAL DIAGRAMS
9
N.E.5
8
N.E.5
7
N.A.1
N.E.5
N.E.7
N.E.6
D1 D3
Q3 Q6
J5 J6
J7 J8 J9
D4 D6
D2 D5
D8
Q1
X94 X96 X95 X97
X13
O
N
S3
O
N
S1
Q24
Q25
Q11
X4
X5
X99
X93 X98
X18
X19
X75
Q10
X33 Q16
BT1
X83 X82 X29
Y1
X28
X81
Y2
X46
X53
R12
R15
R24
DZ31 DZ32
O
N
S2 OCI5 OCI6
J11
X67
X57
D35
J13
X48
L7
X49
Y3
X62
C255
Q20
OCI10 OCI9
C15
X64
X1
X59
Q18
OCI7 OCI8
Q19
D38 D39 D40 D41
X68
C11
J2 J4
X92
X50
C12
C18
D42
X34
R510
R6
R21
X100
X20
X35
X51
D54
D16
X9
D17
X10
X22
C8
Q31 X38
X11
C6
Q14
X41 X25 X36 X85 X12
L14
FTP1
LED9
C9 C10 CT1
X63
D30
T2
OCI12
C14
X70
C13
C19 C22
Q22
C20
C21
C292
X72
L11
FTP3
Q23
L12
X73 X74
D19
D22
X26
X24
X21
N.A.1
7 7
N.A.1
N.E.5
TOP VIEW
10 N.G.1
3
2
ASSEMBLY NOTES
N.A.1 PLACE CONNECTOR KEYING PLUG, , OVER CONNECTOR PIN AT LOCATION SHOWN. PLUG
SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE.
N.A.2 PROGRAM X18 WITH
N.A.3 PROGRAM X32 WITH
N.A.4 PROGRAM X49 WITH
ITEM 8
ITEM 9
.
.
ITEM 13 .
N.A.5 INSERT BT1 INTO ITEM 11 SO (+) FACE (SMOOTH) OF BT1 IS AGAINST THE WALL OF ITEM 11 . THIS
STEP MUST BE PERFORMED DURING PC BOARD TEST ONLY. INSERTING BT1 PRIOR TO TEST CAN
DRAMATICALLY REDUCE LIFE OF BT1. INSERT BT1 WHILE BOARD IS ON A FLAT SURFACE.
N.A.6 PLACE ITEM 12 OVER ITEM 11 . PROTRUSION OF
BOTTOM OF ALL FOUR SIDES OF ITEM 12
ITEM 12 MUST ALIGN WITH PROTRUSION OF ITEM 11
SHOULD BE IN CONTACT WITH SURFACE OF P.C. BOARD
.
BLANK.
ITEM 12 MUST BE PLACED AFTER BT1 IS INSTALLED.
N.A.7 PRINT G6682-[ ] (LATEST DASH NUMBER AND I.D. CODE) ON LABEL AND PLACE OVER THE EXISTING
PART NUMBER IN AREA SHOWN.
ENVIRONMENTAL NOTES
N.E.1 SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM 3 (2 PLACES). HAND TIGHTEN SCREW UNTIL
SCREW HEAD TOUCHES BOARD AND THEN BACK OFF 1/2 TURN.
N.E.2 AFTER POTTING, THE TOPS OF THESE COMPONENTS MUST BE FREE OF MASKING AND POTTING
MATERIAL.
N.E.3 PRIOR TO POTTING APPLY ITEM 5 TO SEAL THE BOTTOM OF THE CONNECTOR CAVITIES TO PREVENT
POTTING MATERIAL FROM GETTING ONTO THE PINS. (AFTER APPLYING GREASE, A NON-PINNNED
MATING CONNECTOR MAY BE USED TO PUSH THE GREASE INTO THE BOTTOM
OF THE CAVITIES.
N.E.4 SEAL BASE OF COMPONENT J15 ON ALL 4 SIDES WITH ITEM 14. RTV MUST FLOW COMPLETELY
AROUND COMPONENT WITH NO GAPS. COMPLETELY COVER MOUNTING HOLES AND BLACK PLASTIC
MOUNTS. ALLOW RTV TO CURE PRIOR TO POTTING.
N.E.5 SEAL BASE OF X18, X19, X20, X32, X47, X48 AND X50 WITH ITEM 14 ON ALL 4 SIDES ON COMPONENT
SIDE OF BOARD. RTV MUST FLOW COMPLETELY AROUND COMPONENTS WITH NO GAPS. ALLOW RTV
TO CURE PRIOR TO POTTING.
N.E.6 PLACE BARCODED ASSEMBLY NUMBER LABEL IN AREA SHOWN.
N.E.7 PLACE BARCODED SERIAL NUMBER ID LABEL IN AREA SHOWN.
N.E.8 PLACE MAC ID NUMBER LABEL IN AREA SHOWN.
N.E.9 AFTER THE POTTING MATERIAL IS CURED, CHECK BOTTOM POTTING TRAY SURFACE FOR WARPAGE.
THE SURFACE IS TO BE FLAT WITHIN .05 F.I.M.
N.E.10 REMOVE PREHEATED ASSEMBLY FROM OVEN AND IMMEDIATELY DISPENSE POTTING MATERIAL
BETWEEN TRAY / BOARD ALLOWING THE MATERIAL TO FLOW UP AROUND ALL FOUR SIDES PRIOR TO
DISPENSING OVER THE TOP. POTTING MATERIAL SHOULD BE TO A MINIMUM DEPTH SUCH THAT ALL
SURFACE MOUNT AND THROUGH-HOLE IC CHIPS, BODIES AND LEADS ARE COVERED. BRUSH COAT
BODIES AND LEADS OF L5, L10, L11, L12 AND L14.
N.E.11 DISPENSE RTV ON SECONDARY SIDE OF BOARD TO COMPLETELY COVER MOUNTING HOLES AND
BLACK PLASTIC MOUNTS FOR BT1 AND J15. ALLOW RTV TO CURE PRIOR TO POTTING.
N.E.12 PRE BAKE UNPOTTED ASSEMBLY FOR 25-35 MINUTES AT 145-155F DEGREES.
N.E.13 POST BAKE POTTED ASSEMBLY FOR 4 HOURS MINIMUM AT 120-125F DEGREES.
GENERAL NOTES
N.G.1 CAUTION: THIS ASSEMBLY IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.
N.G.2 THERE ARE COMPONENTS ON BOTTOM SIDE OF P.C. BOARD.
N.G.3 S1, S2, S3 SWITCHES MUST BE IN THE “ON” POSITION AFTER POTTING,
N.G.4 KEEP AREA AROUND CONNECTOR LOCKING TABS FREE OF POTTING MATERIAL A MINIMUM OF 0.15”
IN ALL DIRECTIONS.
N.G.5 RTV ON BOTTOM SIDE OF BOARD COULD TAKE 4 HOURS MINIMUM AT ROOM TEMPERATURE TO
CURE. RTV MUST BE LEVEL DURING CURE.
N.G.6 RTV ON COMPONENT SIDE OF BOARD COULD TAKE 6 HOURS MINIMUM AT ROOM TEMPERATURE TO
CURE. RTV MUST BE LEVEL DURING CURE.
N.G.7 BOARD MANUFACTURER MAY USE LOCTITE 5140 OR DOW CORNING 3140 IN PLACE OF E2519-1 (ITEM
14) RTV.
10
N.A.7
REVISION CONTROL
G6682-1M0
PART NO. IDENTIFICATION
CODE
TEST PER E4338-C
POT WITHE2527
SCHEMATICREFERENCE: G4799-4M0
BUYAS G6682-1M0 PERE3867
8 LAYERBOARDBLANKPANEL PERE3281-ROHS
SEEELECTRONIC FILE FORADDITIONAL INFORMATION.
G-6
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE t
WITH PUBLISHED STANDARDS.
DO NOT SCALE THIS DRAWING
CONTROL: CLEVELAND
DRAWN BY:
ENGINEER:
APPROVED: fivory
EF
BS
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
SCALE:
2:1
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
POWER SOURCES
DIGITAL CONTROL P.C. BD. ASSEMBLY
8/24/2012
PROJECT
NUMBER:
CRM44934
REFERENCE:
G4800-3
DOCUMENT
NUMBER:
G6682-1
DOCUMENT
REVISION:
F
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Power Wave ® S500
G-7
CONTROL PC BOARD ASSEMBLY (G6682-1 PG 2)
-1 82 G66
ENGINEERING CONTROLLED
MANUFACTURER:
Yes
CHANGE DETAIL: REVISED ITEM 9 PART NUMBER
ELECTRICAL DIAGRAMS G-7
D50
D23
D49
D52
D48
D53
N.G.2
1
N.E.11
Q28
Q29
BOTTOM VIEW
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL AN GLES IS ± .5 OF A DEGREE
CONTROL:
DRAWN BY:
CLEVEL AND fivory
DO NOT SCALE THIS DRAWING
ENGINEER:
APPROVED:
EF
BS
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
SCALE:
2:1
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUI
SU
PMENT TYPE:
BJECT:
MATERIAL
DISPOSITION:
UF APPROVAL
DATE:
POWER SOURCES
DIGITAL CONTROL P.C. BD. ASSEMBLY
8/24/2012 PROJECT
NUMBER:
CRM44934
REFERENCE:
G4800-3
DOCUMENT
NUMBER:
G6682-1
DOCUMENT
REVISION:
F
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Power Wave ® S500
G-8
CONTROL PC BOARD ASSEMBLY (G6682-1 PG 3)
-1 82 G66
ENGINEERING CONTROLLED
MANUFACTURER:
Yes
CHANGE DETAIL:
REVISED ITEM 9 PART NUMBER
3
4
5
6
ITEM USED WITH *
1
2
7
8 (X18)*
9 (X32)*
10 (D30, Q21)*
11 (BT1)*
12 (BT1)*
13 (X49)*
14
QTY
1
1
PART NUMBER
G4800-M
M19436-14
2 S8025-80
10.2 oz E2527
0.16 oz E3539
0.18 oz E2861
4
1
1
2
1
1
1
.25 oz
S24671
Y00556-2
S26773-12
S20590-6
S25125-2
S27541
Y01310
E2519-1
DESCRIPTION
PC BOARD BLANK
POTTING TRAY
SELF TAPPING SCREW
EPOXY ENCAPSULATING RESIN
ELECTRICAL INSULATING COMPOUND
RTV COMPOUND
PLUG, KEYING PLUG
FIRMWARE FOR CPLD
SOFTWARE FOR FLASH
HEAT SINK,CLIP-ON,STAND-UP,FOR TO-220
BATTERY HOLDER,VERTICAL 20mm COINCELL,SLIMLINE
BATTERY COVER
FIRMWARE FOR CLOCK GENERATOR
RTV COMPOUND
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
REFERENCES
BT1
C4, C7, C70, C83, C175, C261
C6, C8
C9, C10, C15, C18, C19, C20, C21
C11, C12
C13, C22
C14, C17
C16, C54, C58, C60, C62, C63, C66,
C67, C69
C23, C24, C27, C28, C33, C34, C35,
C36, C37, C38, C79, C81, C82, C84,
C85, C88, C89, C119, C134, C135,
C138, C149, C249, C267, C268, C271,
C282, C298, C300, C301, C302, C328,
C329, C343, C344
C25, C26, C29, C32, C293
C30, C31, C169, C256, C283, C286,
C288, C291
C39, C90, C92, C99, C131, C180,
C183, C185, C188, C223, C227, C228,
C244, C304, C348
C40, C42, C45, C46, C47, C48, C50,
C51, C52, C53, C57, C91, C93, C94,
C95, C96, C97, C98, C100, C101,
C102, C103, C104, C105, C106, C107,
C108, C109, C111, C112, C113, C114,
C130, C133, C141, C142, C143, C144,
C145, C146, C147, C148, C150, C151,
C152, C153, C154, C155, C156, C157,
C158, C159, C160, C161, C162, C163,
C164, C165, C166, C167, C177, C178,
C179, C182, C186, C187, C189, C190,
C191, C193, C195, C196, C197, C198,
C200, C201, C202, C203, C204, C205,
C206, C207, C208, C209, C210, C211,
C212, C213, C215, C217, C218, C219,
C220, C229, C230, C231, C232, C233,
C234, C235, C236, C237, C238, C239,
C240, C241, C242, C243, C262, C264,
C266, C269, C270, C272, C273, C274,
C278, C279, C280, C281, C305, C306,
C309, C310, C311, C312, C314, C315,
C320, C321, C322, C327, C335, C336,
C337, C359, C360, C361, C362, C363,
C364, C365, C366, C367
C41, C43, C44, C71, C72, C171, C174,
C216, C251, C257, C285, C290
C56, C61, C168, C246, C250, C254,
C284, C289, C345, C346, C347
C73, C181, C184, C263, C265, C316,
C317
C77, C132, C296, C299, C303
C80
C110, C255, C287, C292, C325
C120, C129, C247, C294, C307, C313,
C323, C324
C170, C258
C172, C221, C222, C226, C253, C260,
C349
C173, C259, C338, C339, C340
C224, C225
C245, C248
C252
C295
C297
D1, D2, D3, D4, D5, D6, D8, D38, D39,
D40, D41, D48, D53
D7, D9, D10, D11, D37, D44, D45, D46,
D47, D54
D16, D17, D22, D23, D50
D19, D49, D52
D30
D35
D42
D43, D55, D56, D57, D58
DZ1, DZ2, DZ3, DZ4, DZ5, DZ6, DZ7,
DZ8, DZ21
DZ9, DZ10, DZ11, DZ12, DZ31, DZ32
DZ23
DZ24
DZ26, DZ27, DZ28, DZ29, DZ30
QTY
1
6
2
7
2
2
2
9
35
5
8
15
144
12
11
7
5
1
5
8
2
7
2
1
5
2
1
1
13
10
9
6
1
1
5
1
1
5
3
1
5
PART NUMBER
S25125-3
S25020-2SMT
S25030-2SMT
S13490-197
S13490-184
S13490-198
S20500-16
S25020-4SMT
S25020-27SMT
S25020-5SMT
S25020-3SMT
S25020-32SMT
S25020-30SMT
S25020-24SMT
S25020-10SMT
S25020-15SMT
S25020-13SMT
S25020-41SMT
S25020-29SMT
S25020-33SMT
S25020-38SMT
S25020-22SMT
S25020-14SMT
S25020-31SMT
S25020-8SMT
S25020-25SMT
S25020-6SMT
S25020-12SMT
S25040-5SMT
S25040-2SMT
S25040-6SMT
S25049-4SMT
T12705-63
S25049-3SMT
S25040-4SMT
S25040-11SMT
S25046-1SMT
S25044-9SMT
S25044-7SMT
S25044-12SMT
S25046-3SMT
DESCRIPTION
BATTERY,LITHIUM,PLOYCMF,20MM COIN,3V,190MAH
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
CAPACITOR,SMD,METAL FILM,0.1MF,50V,5%,PPS
CAPACITOR,ALEL,82,35V,20%,LOW-ESR
CAPACITOR,ALEL,330,100V,20%
CAPACITOR,ALEL,1000,35V,20%,LOW-ESR
CAPACITOR,PPMF,0.0033,630V,5%,BOX
CAPACITOR,SMD,CERAMIC,820pF,50V,5%,COG,S0805
CAPACITOR,SMD,CER,0.1MF,50V,-20%+80%,Z5U,S0805
CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
CAPACITOR,SMD,CERAMIC,10MF,6.3V,20%,X5R,S0805
CAPACITOR,SMD,CERAMIC,0.22MF,10V,10%,X7R,S0603
CAPACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805
CAPACITOR,SMD,CERAMIC,22PF,50V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,150pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,560pF,50V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,10MF,25V,20%,X5R,S1210
CAPACITOR,SMD,CERAMIC,10MF,10V,20%,X5R,S1206
CAPACITOR,SMD,CERAMIC,100MF,6.3V,20%,X5R,S1206
CAPACITOR,SMD,CERAMIC,0.01MF,200V,20%,X7R,S1206
CAPACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,270pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,0.056MF,50V,10%,X7R,S0805
CAPACITOR,SMD,CERAMIC,4.7MF,16V,10% ,X7R,S1210
CAPACITOR,SMD,CERAMIC,4700pF,50V,5%,COG,S1206
CAPACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805
DIODE,SMD,DUAL,0.200A,70V,UFR
DIODE,SMD,1A,400V,DO-214BA/AC
DIODE,SMD,DUAL,0.200A,70V,UDR,CC,SOT-23
DIODE,SMD,SCHOTTKY,DUAL,0.200A,30V,SOT-23
DIODE,SCHOTTKY,TO220,8A,100V,MBR10H100
DIODE,SMD,SCHOTTKY,3A,40V,CASE 403-3
DIODE,SMD,DUAL,0.200A,70V,UFR
DIODE,SMD,1A,600V,S403A,ULTRA-FAST RECOVERY
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
ZENER DIODE,SMD,3W,6.2V,5%, SMB
ZENER DIODE,SMD,3W,56V,5%, SMB
ZENER DIODE,SMD,3W,3.3V,5%, SMB
ZENER DIODE,SMD,0.5W,18V, 5%,SOD123
ELECTRICAL DIAGRAMS
N.E.3
J2, J5, J11
J3
J4
J6, J7
J8
J9, J13
J12
N.E.4
J15
L1, L2, L4, L6, L7, L8, L9, L13
L5, L10
L11, L12
L14
LED1, LED3, LED4, LED5, LED6,
LED7, LED8, LED9, LED10
LED2
OCI1, OCI2
OCI5
OCI6, OCI7, OCI8
OCI9, OCI10
OCI12
Q1, Q3, Q6, Q14, Q31
Q10, Q11, Q18, Q19, Q24, Q25, Q28,
Q29
Q16, Q20, Q22, Q23
Q21
R1, R206, R207, R448
R2, R428, R564, R565, R566, R567,
R568, R598, R599, R600, R601, R602,
R603
R3, R476, R477
R4
R6, R12, R15, R21, R24, R510
R30, R33, R61, R65, R124, R125, R196,
R210, R302, R307, R335, R354, R407,
R432, R439, R529, R530, R586, R587
R31, R38, R62, R64, R150, R312
R32, R36, R52, R55, R152, R158, R172,
R174, R175, R178, R290, R293, R299,
R303, R305, R309, R433, R453
R34, R313, R378, R379, R380, R382,
R385, R387, R429, R436, R464, R467,
R470, R473, R594, R595, R609, R610,
R611
R35, R71, R89, R92, R94, R106, R107,
R110, R192, R211, R213, R214, R216,
R218, R219, R220, R221, R222, R223,
R224, R225, R227, R230, R231, R232,
R233, R234, R238, R239, R321, R322,
R343, R348, R349, R350, R352, R353,
R355, R375, R376, R377, R383, R386,
R389, R426, R475, R496, R497, R498,
R499, R500, R501, R513, R514, R515,
R516, R517, R518, R519, R520, R521,
R522, R523, R524, R525, R527, R569,
R606, R607, R608, R613
R39, R44, R45, R48, R49, R50, R51,
R53
R41, R43, R47, R54
R42, R162
R46, R167
R56, R203, R440
R57, R58, R336, R406
R59, R200
R60, R63, R235, R236, R237, R248,
R414, R418
R73
R75
R78
R81, R83, R85, R93, R96, R98, R100,
R260, R266, R479, R584, R585, R591
R84, R86, R87, R88, R90, R102, R128,
R132, R592
R91, R95
R97, R99, R183
R101, R191, R288, R431, R438
R103
R108, R109, R115, R116, R120, R127,
R204, R319, R329, R332, R333, R338,
R367, R368, R369, R370, R371, R410,
R413, R417, R483, R502, R503, R504,
R505, R506, R507, R508, R509, R526,
R557, R577, R578, R579, R580, R581,
R582, R583
R111, R112, R117, R118, R121, R209,
R388, R427, R434
R126
R129
R130, R136
R131
R133, R134, R138, R139, R140, R144
R135, R137, R141, R142, R143, R145
R147, R201, R294, R320, R323
R155
13
3
1
6
1
8
2
2
1
9
2
1
2
1
3
1
1
1
2
1
3
2
1
5
8
4
1
4
19
6
18
19
71
8
1
1
1
8
2
3
4
2
4
2
13
9
2
3
5
1
38
9
5
1
6
6
1
1
2
1
S24020-4
S18248-10
S24020-10
S24020-16
S24020-8
S24020-6
S24020-12
S25104-1
S25083-6SMT
S25083-8SMT
S25083-7SMT
S25083-4SMT
S25080-2SMT
S25080-1SMT
S15000-36SMT
S15000-28SMT
S15000-35SMT
S15000-32SMT
S15000-34SMT
S25051-7SMT
S25050-2SMT
S25051-15SMT
S18395-55
TRANSISTOR,SMD,NMF,7.3A,30V,SO-8
HEAT SINK ASSEMBLY,T12704-110 & S20590-6 (SS)
S25012-4751SMT RESISTOR,SMD,METAL FILM,1/16W,4.75K,1%,S0603
S25012-1301SMT RESISTOR,SMD,METAL FILM,1/16W,1.30K,1%,S0603
S25003-2000SMT RESISTOR,SMD,1W,200OHMS,1%
S25003-1210SMT RESISTOR,SMD,1W,121OHMS,1%
S25013-1SMT
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,10-PIN
CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
CONNECTOR,MODULAR,HIGH-SPEED,VERTICAL,INTERNAL-
SHIELD,8/8
CHOKE,SMD,RF,FERRITE_BEAD,600 OHMS
CHOKE,SMD,POWER,27UH,10%,1.75A
CHOKE,SMD,POWER,18UH,20%,3.9A,LS127-180-RM
CHOKE,SMD,POWER,10UH,10%,1.02A,
LED,SMD,GREEN,CLEAR,S1206
LED,SMD,RED,CLEAR,S1206
OPTOCOUPLER,SMD,TTL-OUT,DUAL,HIGH-SPEED
OPTOCOUPLER,SMD,TTL-OUT,HI-SPD,HI-CMR
OPTOCOUPLER,SMD,3.3V,HIGH-SPEED,HCPL060L,SO8
OPTOCOUPLER,SMD,CMOS,HIGH SPEED,HIGH CMR,SO-8(SS)
IC,SMD,OPTOCOUPLER,HMA124
TRANSISTOR,SMD,NMF,SO-8,3A,50V
TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
RESISTOR,ARRAY,SMD,MF,1/16W,22OHM,8-PIN
S25012-1002SMT RESISTOR,SMD,METAL FILM,1/16W,10.0K,1%,S0603
S25012-1503SMT RESISTOR,SMD,METAL FILM,1/16W,150K,1%,S0603
S25012-1003SMT RESISTOR,SMD,METAL FILM,1/16W,100K,1%,S0603
S25012-1000SMT RESISTOR,SMD,METAL FILM,1/16W,100OHMS,1%,S0603
S25012-3321SMT RESISTOR,SMD,METAL FILM,1/16W,3.32K,1%,S0603
S25001-5622SMT RESISTOR,SMD,56.2K,1/4W,1206,1%,TR
S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
S25012-1004SMT RESISTOR,SMD,METAL FILM,1/16W,1.00M,1%,S0603
S25012-6191SMT RESISTOR,SMD,METAL FILM,1/16W,6.19K,1%,S0603
S25012-2001SMT RESISTOR,SMD,METAL FILM,1/16W,2.00K,1%,S0603
S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
S25012-3322SMT RESISTOR,SMD,METAL FILM,1/16W,33.2K,1%,S0603
S25012-6811SMT RESISTOR,SMD,METAL FILM,1/16W,6.81K,1%,S0603
S25000-6812SMT RESISTOR,SMD,METAL FILM,1/10W,68.1K,1%,S0805
S25000-1003SMT RESISTOR,SMD,METAL FILM,1/10W,100K,1%,S0805
S25000-2212SMT RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
S25001-2210SMT RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
S25001-4750SMT RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR
S25001-1211SMT RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
S25001-2211SMT RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
S25012-4750SMT RESISTOR,SMD,METAL FILM,1/16W,475OHMS,1%,S0603
S25000-2672SMT RESISTOR,SMD,METAL FILM,1/10W,26.7K,1%,S0805
S25012-1001SMT RESISTOR,SMD,METAL FILM,1/16W,1.00K,1%,S0603
S25012-2212SMT RESISTOR,SMD,METAL FILM,1/16W,22.1K,1%,S0603
S25000-4753SMT RESISTOR,SMD,METAL FILM,1/10W,475K,1%,S0805
S25000-2211SMT RESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805
S25001-47R5SMT RESISTOR,SMD,47.5OHMS,1/4W,1206,1%,TR
S25001-4751SMT RESISTOR,SMD,4.75K,1/4W,1206,1%,TR
S25000-1000SMT RESISTOR,SMD,METAL FILM,1/10W,100OHMS,1%,S0805
S25001-3320SMT RESISTOR,SMD,332OHMS,1/4W,1206,1%,TR
S25000-5620SMT RESISTOR,SMD,METAL FILM,1/10W,562OHMS,1%,S0805
S25000-3741SMT RESISTOR,SMD,METAL FILM,1/10W,3.74K,1%,S0805
N.G.3, N.E.2
N.A.2
N.A.3
N.A.4
R156, R291, R571, R572, R573, R574,
R575, R576
R159, R160, R289, R300
R164, R165, R171, R173, R176, R177,
R180, R181
R168, R212, R443, R444
R169, R170, R208, R345, R441, R570
R179, R182
R189
R215
R240, R241, R243, R252, R411, R412,
R419
R258, R262, R263, R264, R478, R480
R298, R449
R310
R324
R325, R326, R327, R328, R481
R334, R390, R392, R393, R394, R405
R337, R408
R340
R344
R346, R347, R455, R456
R381, R384
R391, R465, R468, R471, R474
R395, R397, R401, R402
R396, R398
R400
R403, R404, R459, R461
R409
R415
R416
R420, R445
R421, R447, R454
R430, R437
R435, R451
R442, R446
R450
R452
R457, R458, R460, R462
R463, R466, R469, R472
R485
S1, S2, S3
T1
T2
X1
X4, X92, X100
X5
X8
X9, X10, X12, X26, X38, X85
X11
X13
X14, X15, X67
X18
X19
X20
X21, X36
X22, X34, X74
X24
X25
X28
X29
X32
X33, X62, X72, X73
X35, X46, X51, X53
X39, X40, X65, X79
X41, X71
X47
X48
X49
X50
X52
X54
X57, X59, X70
X58, X60, X61
X63
X64
X68
X69
X75
X77, X78
X81, X82, X83
X93, X94, X95, X96, X97, X98, X99
Y1
Y2, Y3
2
1
1
4
6
7
1
1
1
1
1
4
1
2
3
2
1
1
4
4
1
1
1
1
3
1
3
1
4
4
1
1
1
3
1
6
1
1
1
1
3
1
1
1
1
1
3
7
1
2
2
3
4
1
2
1
1
1
2
5
4
2
2
2
2
3
1
1
6
2
1
1
4
6
2
1
1
5
8
4
8
S25001-26R7SMT RESISTOR,SMD,26.7OHMS,1/4W,1206,1%,TR
S25000-3921SMT RESISTOR,SMD,METAL FILM,1/10W,3.92K,1%,S0805
S25007-1002SMT RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.1%,S0805
S25001-1501SMT RESISTOR,SMD,1.5K,1/4W,1206,1%,TR
S25012-2671SMT RESISTOR,SMD,METAL FILM,1/16W,2.67K,1%,S0603
S25001-2000SMT RESISTOR,SMD,200OHMS,1/4W,1206,1%,TR
S25012-1502SMT RESISTOR,SMD,METAL FILM,1/16W,15.0K,1%,S0603
S25012-2000SMT RESISTOR,SMD,METAL FILM,1/16W,200OHMS,1%,S0603
S25000-2000SMT RESISTOR,SMD,METAL FILM,1/10W,200OHMS,1%,S0805
S25001-1500SMT RESISTOR,SMD,150OHMS,1/4W,1206,1%,TR
S25012-5111SMT RESISTOR,SMD,METAL FILM,1/16W,5.11K,1%,S0603
S25000-6811SMT RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
S25000-1501SMT RESISTOR,SMD,METAL FILM,1/10W,1.50K,1%,S0805
S25000-4750SMT RESISTOR,SMD,METAL FILM,1/10W,475OHMS,1%,S0805
S25003-15R0SMT RESISTOR,SMD,1W,15.0OHMS,1%
S25000-5621SMT RESISTOR,SMD,METAL FILM,1/10W,5.62K,1%,S0805
S25000-1372SMT RESISTOR,SMD,METAL FILM,1/10W,13.7K,1%,S0805
S25000-9091SMT RESISTOR,SMD,METAL FILM,1/10W,9.09K,1%,S0805
S25000-10R0SMT RESISTOR,SMD,METAL FILM,1/10W,10.0OHMS,1%,S0805
S25000-47R5SMT RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
S25001-2671SMT RESISTOR,SMD,2.67K,1/4W,1206,1%,TR
S25001-4752SMT RESISTOR,SMD,47.5K,1/4W,1206,1%,TR
S25001-3321SMT RESISTOR,SMD,3.32K,1/4W,1206,1%,TR
S25000-3321SMT RESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805
S25003-0R10SMT RESISTOR,SMD,1W,0.1OHMS,1%
S25000-2802SMT RESISTOR,SMD,METAL FILM,1/10W,28.0K,1%,S0805
S25000-3570SMT RESISTOR,SMD,METAL FILM,1/10W,357OHMS,1%,S0805
S25000-2210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
S25000-5110SMT RESISTOR,SMD,METAL FILM,1/10W,511OHMS,1%,S0805
S25012-1501SMT RESISTOR,SMD,METAL FILM,1/16W,1.50K,1%,S0603
S25001-15R0SMT RESISTOR,SMD,15.0OHMS,1/4W,1206,1%,TR
S25012-2211SMT RESISTOR,SMD,METAL FILM,1/16W,2.21K,1%,S0603
S25001-1821SMT RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
S25000-2430SMT RESISTOR,SMD,METAL FILM,1/10W,243OHMS,1%,S0805
S25012-3162SMT RESISTOR,SMD,METAL FILM,1/16W,31.6K,1%,S0603
S25003-20R0SMT RESISTOR,SMD,1W,20.0OHMS,1%
S25012-6810SMT RESISTOR,SMD,METAL FILM,1/16W,681OHMS,1%,S0603
S25000-7500SMT RESISTOR,SMD,METAL FILM,1/10W,750OHMS,1%,S0805
S19869-43
S25067-13SMT
S20375-24
S25065-12SMT
S25072-2SMT
M15102-4SMT
SWITCH_SLIDE_3PSTX1
IC,SMD,TRANSFORMER MODULE,10/100BASE-T LAN MAGNETICS
TRANSFORMER,PWM,FLYBACK,ICE-1513
IC,SMD,CMOS,BUFFER,SINGLE-BUS(SS)
IC,SMD,ACT,BUFFER,OCTAL,3-STATE,TSSOP-20(SS)
IC,SMD,ARRAY,DRIVER,PERIPHERAL,NPN,DARLINGTON
S25068-24SMT
S15128-28SMT
S25067-2SMT
S24841-3
S20353-4SMT
S25070-22SMT
S25070-20SMT
IC,SMD,REGULATOR,1.2V-5V,TPS72501(SS)
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
IC,SMD,CMOS,MULTILPLEXER,DIFF,4-1 CHANNEL
IC,MODULE,CONVERTER,DC-DC,5V/0.15A-OUT,5.25V-IN
IC,SMD,CMOS,XCVR,EIA485(SS)
IC,SMD,CMOS,CPLD,XC9572XL,BGA-48(SS)
IC,SMD,FPGA,EP1C6F256I8,256-PIN,BGA(SS)
S25073-5SMT
S25057-5SMT
S15128-11SMT
S15018-11SMT
S15128-13SMT
S25069-22SMT
S25069-21SMT
S25069-19SMT
S25068-23SMT
S25069-18SMT
S25065-6SMT
S15128-10SMT
S25073-6SMT
S25070-21SMT
S25070-18SMT
S25073-10SMT
IC,SMD,CMOS,DSP,32-BIT,179-PIN BGA,TMS320F2812(SS)
POT,SMD,DIGITAL,20K,QUAD,TSSOP-24
IC,SMD,COMPARATOR,QUAD,2901D
IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS)
IC,SMD,OP-AMP,SINGLE,PRECISION,OP-27GS8,SOIC-8
IC,SMD,CMOS,EEPROM,SERIAL,512K,2.7V,SOIC-8M(SS)
IC,SMD,CMOS,NVRAM,256MB,SOIC-14(SS)
IC,SMD,3V,MEMORY,FLASH,128Mb,BGA64,(SS)
IC,SMD,VOLTAGE REGULATOR,4.5V-20V,TPS54350
IC,SMD,CMOS,SDRAM,64MB,TSOP54(SS)
IC,SMD,CMOS,INVERTER,SCHMITT,DUAL(SS)
IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8
IC,SMD,CMOS,MCU,32-BIT,BGA,388-PIN(SS)
IC,SMD,CMOS,TRANSCEIVER,ETHERNET,PBGA-64(SS)
IC,SMD,EPROM,CLOCK-GENERATOR,CY2292(SS)
IC,SMD,CMOS,DSP,BGA,288-PIN,TMS320C6413(SS)
S25068-10SMT
S15128-5SMT
S25068-16SMT
S25065-5SMT
S25068-25SMT
S25068-4SMT
S25065-4SMT
M15458-4SMT
S25065-7SMT
S25072-3SMT
S20353-7SMT
S25065-10SMT
S25082-6SMT
S25082-7SMT
IC,SMD,VOLTAGE REGULATOR,FIXED,3-TERMINAL,0.5A,-15V
IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
IC,SMD,VOLT.REGULATOR,ADJ,0.8A,LM1117(SS)
IC,SMD,CMOS,INVERTER,SCHMITT,SINGLE(SS)
IC,SMD,VOLTAGE-REFERENCE,1.2V,0.2%,SOT-23(SS)
IC,SMD,TRANSCEIVER,CAN,UC5350,S0IC-8
IC,SMD,CMOS,TRANSCEIVER,3V-5.5V,MAX3221,(SS)
IC,SMD,PWM-CONTROLLER,I-MODE,2842A, SOIC-8
IC,SMD,CMOS,INVERTER,SINGLE(SS)
IC,SMD,ACT,BUFFER,OCT,3-STATE,3.3V,TSSOP-20(SS)
IC,SMD,CMOS,XCVR,ADM1485(SS)
IC,SMD,CMOS,AND,SINGLE,2-INPUT(SS)
CRYSTAL,SMD,32.768kHZ
CRYSTAL,SMD,12MHZ
UNLESS OTHERWISE SPECIFIED:
CAPACITANCE = MFD/VOLTS
INDUCTANCE = HENRIES
RESISTANCE = OHMS
G-8
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE
CONTROL: CLEVELAND
DRAWN BY: fivory
ENGINEER: EF
DO NOT SCALE THIS DRAWING APPROVED:
BS
SCALE:
2:1
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
POWER SOURCES
DIGITAL CONTROL P.C. BD. ASSEMBLY
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
8/24/2012
PROJECT
NUMBER:
CRM44934
REFERENCE:
G4800-3
DOCUMENT
NUMBER:
G6682-1
DOCUMENT
REVISION:
F
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Power Wave ® S500
G-9
PFC CONTROL BOARD ASSEMBLY (G6860-1 PG 1)
ELECTRICAL DIAGRAMS
-1 60 G68
ENGINEERING CONTROLLED
MANUFACTURER:
Yes
CHANGE DETAIL: ADDED TABLE AND NOTES PER TABLE. REVISED NOTE N.E.1
REVISION CONTROL
G6860-1D3
PART NO. IDENTIFICATION
CODE
TEST PER E4734-IC
POT WITH E2527
SCHEMATIC REFERENCE: G6859-1D3
MAKE DETAIL
MANUFACTUREPERE1911-RoHS
BUY BLANK COMPLETE
(4 BOARDS PER PANEL)
4 LAYER BOARD BLANK PANEL
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION.
6.84
6.50
N.E.1
N.E.1
6.49
6.15
N.E.1
J23A
Q9
X1
Q2
C13
X13
C16
D5 D6
X2
C1
X8
C14
X14
X21
FTP26
FTP15
Q3 D49
OCI1
D26
FTP21
X31
X26 OCI5
X27
FTP17
DZ19
X9
DZ20
FTP29
D61
C33
D7
X3
C4
FTP9
D9
D10
X4
C5
T1
C6
FTP7
D11
C7
FTP8
D12 X5
D18 D19 D20
X6
J23B
OCI2
D27
X18 X19 X17 X16
D28
R257
OCI3
Y2
J2
1
FTP5
LED2
LED5
1 J1
FTP6
FTP38
X10
FTP12
FTP11
FTP2
D36 D33 D35 D38 D34 D37
C29
D56
D57
C30
FTP40
D62
X24
Q8
LED1
D29
OCI4
X20
X25
X29 X30 Q7
D51
C10
X12
Q1
X7
Q10
C20
C31
C32
D67 D66
Q6
C34
G6860-1
D69
R212
FTP3
N.P.T.2
COMPONENT SIDE
SCALE = 1:1
N.E.1
N.E.1
4
6
2
N.E.4
N.A.2
PART NO.
G6860-1D3HPT
G6860-1
TABLED NOTES
N.P.T.1., N.P.T.2.
ASSEMBLY NOTES:
N.A.2
SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM 6
TOUCHES BOARD AND THEN BACK OFF 1/2 TURN.
(2 PLACES). TIGHTEN UNTIL SCREW HEAD
N.A.3
PROGRAM X24 WITH ITEM 7 (AFTER ASSEMBLY).
N.A.4
PROGRAM X22 WITH ITEM 8 (AFTER ASSEMBLY).
ENVIRONMENTAL NOTES:
N.E.1
PRIOR TO POTTING, CONNECTORS MUST BE GREASED WITH ITEM 5 .
N.E.3
DISPENSE POTTING MATERIAL TO A MINIMUM DEPTH SUCH THAT ALL COMPONENT LEADS ARE
COVERED.
N.E.4
PLACE BAR CODED ASSEMBLY NUMBER AND BAR CODED SERIAL NUMBER IDENTIFICATION IN AREA
SHOWN.
GENERAL NOTES:
N.G.1. CAUTION: THIS ASSEMBLY IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.
SEE E2454 BEFORE HANDLING. THIS ASSEMBLY IS NO LONGER ESD SENSITIVE AFTER POTTING.
NOTES PER TABLE:
N.P.T.1.
MAKE G6860-[LATEST VERSION]HPT BY TESTING PER SPECIAL TEST INSTRUCTIONS PER E4734I C.
N.P.T.2.
PRINT “FOR PARTS ORDERS ONLY” ON E3768-4 LABEL AND PLACE ON SIDE OF POTTING TRAY
AS SHOWN.
N.E.4 2
N.E.3 3
4
ITEM
1
N.E.1 5
N.A.2 6
N.A.3 7
N.A.4 8
QTY
1
2
224 g.
1
7 g.
2
1
1
PART NUMBER
G6860-D
E3768-4
E2527
M19436-24
E2543
S8025-80
Y00562-02
Y01623-03
DESCRIPTION
PC BOARD BLANK
LABEL 0.25 X 2.50
EPOXY ENCAPSULATING RESIN
POTTING TRAY
ELECTRICAL INSULATING COMPOUND
#6 SELF TAPPING SCREW
SOFTWARE
SOFTWARE
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
REFERENCES
C1, C2, C3, C8, C9, C10,
C11, C21, C23, C24, C25,
C26, C27
C4, C5, C6, C7
C12, C20
C13, C15, C17
C14, C16
QTY
13
4
2
3
2
PART NUMBER
S13490-173
S25024-9SMT
S25020-1SMT
S25026-2SMT
S25024-10SMT
DESCRIPTION
CAPACITOR,PEMF,1.0,63V,10%
CAPACITOR,SMD,TANTALUM,100MF,20V,20%,S7343
CAPACITOR,SMD,CERAMIC,0.022MF,50V,1%,COG,S1825
CAPACITOR,SMD,TANTALUM,100MF,16V,20%,S7343,LOW-
ESR,SURGE
CAPACITOR,SMD,TANTALUM,22MF,25V,10%,S7343
C18, C28, C36, C37, C38,
C42, C43, C44, C45, C46,
C47, C48, C54, C55, C56,
C57, C58, C59, C62, C63,
C72, C76, C77, C78, C79,
C82, C83, C84, C89, C90,
C91, C92, C93, C94,
C100, C119, C120, C125,
C128, C131, C132, C136,
C141, C142, C143, C145,
C146, C147, C149
C19, C35, C150
C22, C41, C49, C73, C81,
C121, C138, C139
C29, C30, C32
C31
C33
C34
C39, C66, C74, C75
C40, C50, C64, C65, C67,
C68, C69, C70, C71,
C122, C151
C51, C53, C60, C61,
C148
C52
C80, C101, C130
C85, C86, C87, C88, C95,
C96, C97, C98, C99,
C102, C103, C104, C105,
C106, C107, C108, C109,
C110, C111, C113, C114,
C115, C116, C117, C118,
C124, C126, C133, C135,
C155, C156, C157, C158
C123, C127
C129
C137, C140, C144
C152, C153
C154
C159, C160, C161
C162, C163
D1, D2, D3, D4, D5, D6,
D7, D8, D13, D14, D15,
D16, D17, D18, D19, D20,
D21, D22, D23, D24, D30,
D31, D39, D40, D41, D42,
D43, D44
D9, D10, D11, D12, D26,
D27, D28, D29, D45, D46,
D47, D48, D49, D50, D52,
D53, D54, D55, D56, D57,
D58, D65, D68
D25
D32, D66, D67
D33, D34, D35, D36, D37,
D38
D51
D59, D60, D61, D69
D62, D63, D64
DZ1, DZ2, DZ3, DZ4, DZ5,
DZ6, DZ7, DZ8, DZ9
DZ10, DZ17, DZ18, DZ22
DZ11, DZ12
DZ19, DZ20
J1, J2
N.E.1 J20, J21
N.E.1 J22, J26
N.E.1 J24
N.E.1 J25
N.E.1 J23A, J23B
L1
LED1
LED2, LED5
LED3, LED4
OCI1, OCI2, OCI3, OCI4
OCI5
Q1, Q2, Q3, Q9, Q10
Q4
Q6, Q8
Q7
R1, R10, R19, R21, R22,
R24, R35, R36, R37, R41,
R42, R43, R51, R52, R58,
R59, R65, R66, R67, R69,
R82, R83, R85, R89,
R113, R114, R137
R2
R3, R4, R7, R8
R5, R6, R13, R17
R9, R74, R117, R151
49
3
8
1
1
3
1
4
11
5
1
3
33
2
1
3
2
1
3
2
28
23
1
3
6
1
4
3
9
1
2
2
1
2
4
2
1
1
1
2
1
5
4
2
2
2
2
1
27
1
4
4
4
S25020-3SMT
S25020-15SMT
S25020-2SMT
S13490-197
S20500-1
S13490-230
S13490-198
S25020-27SMT
S25020-6SMT
S25020-14SMT
S25020-22SMT
S25020-12SMT
S25020-30SMT
S25020-33SMT
S25024-8SMT
S25020-13SMT
S25020-24SMT
S25020-35SMT
S25020-10SMT
S25020-43SMT
S25049-2SMT
S25040-1SMT
S25049-3SMT
S25049-1SMT
S25049-4SMT
T12705-58
S25040-8SMT
S25040-18SMT
S25046-1SMT
S25044-5SMT
S25046-4SMT
S25044-9SMT
S26770-10SMT
S24020-4
S24020-6
S24020-8
S24020-12
S24020-16
S25083-3SMT
S25080-4SMT
S25080-1SMT
S25080-2SMT
S15000-28SMT
S15000-22SMT
S25051-4SMT
S25051-6SMT
S27524
S25050-2SMT
CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
CAPACITOR,SMD,CERAMIC,22PF,50V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
CAPACITOR,ALEL,82,35V,20%,LOW-ESR
CAPACITOR,PPMF,0.1,1000V,10%,BOX
CAPACITOR,ALEL,220,63V,20%
CAPACITOR,ALEL,1000,35V,20%,LOW-ESR
CAPACITOR,SMD,CER,0.1MF,50V,-20%+80%,Z5U,S0805
CAPACITOR,SMD,CERAMIC,4700pF,50V,5%,COG,S1206
CAPACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,0.01MF,200V,20%,X7R,S1206
CAPACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,0.22MF,10V,10%,X7R,S0603
CAPACITOR,SMD,CERAMIC,10MF,10V,20%,X5R,S1206
CAPACITOR,SMD,TANTALUM,10MF,16V,10%,S6032
CAPACITOR,SMD,CERAMIC,150pF,100V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206
CAPACITOR,SMD,CERAMIC,680pF,50V,5%,COG,S0805
CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805
CAPACITOR,SMD,CERAMIC,2.2MF,10V,10%,X7R,S0805
DIODE,SMD,SCHOTTKY,1A,30V,SMA
DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA
DIODE,SMD,SCHOTTKY,3A,40V,CASE 403-3
DIODE,SMD,SCHOTTKY,0.5A,30V,SOD-123
DIODE,SMD,SCHOTTKY,DUAL,0.200A,30V,SOT-23
DIODE,D204AL,1A,1500V
DIODE,SMD,3A,600V,D0-214AB,ULTRA-FAST RECOVERY
DIODE,SMD,1A,1300V,DO-214BA
ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
ZENER DIODE,SMD,3W,18V,5%, SMB
ZENER DIODE,SMD,0.5W,12V,5%,SOD-123
ZENER DIODE,SMD,3W,6.2V,5%, SMB
CONNECTOR,SMD,SOCKET,LOW-PROFILE,10-PIN
CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN
CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN
CHOKE,SMD,POWER,47UH,10%,1.25A,
LED,SMD,BI-COLOR,RED/GREEN,HSMF-C655
LED,SMD,RED,CLEAR,S1206
LED,SMD,GREEN,CLEAR,S1206
OPTOCOUPLER,SMD,TTL-OUT,HI-SPD,HI-CMR
OPTOCOUPLER,SMD,PHOTO-TRANSISTOR,70V,CNY1733SD
TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,7002LT1(SS)
TRANSISTOR,SMD,NMF,DPAK,TO-252,10A,100V(SS)
HEAT SINK ASSEMBLY,T12704-117 & S20590-3 (SS)
TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
S25012-3321SMT RESISTOR,SMD,METAL FILM,1/16W,3.32K,1%,S0603
S25014-0R10SMT RESISTOR,SMD,METAL-STRIP,5W,0.1OHM,1%
S25003-1210SMT RESISTOR,SMD,1W,121OHMS,1%
S25001-1210SMT RESISTOR,SMD,121OHMS,1/4W,1206,1%,TR
S25012-1001SMT RESISTOR,SMD,METAL FILM,1/16W,1.00K,1%,S0603
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
REFERENCES QTY PART NUMBER DESCRIPTION
R11, R12, R18, R20, R25,
R26, R38, R39, R53, R55,
R61, R62, R63, R64, R87,
R88, R109
R14, R16, R27, R44, R92,
R110
R15, R30, R47, R50, R222
R220
R248, R249, R250, R251
R256, R257, R258, R259
T1
T2
X1, X7, X25
X2, X3, X5, X6, X16, X17,
X18, X19
X4, X8, X12
X9
X10
X13
X14
X20
X21
N.A.4 X22
N.A.3 X24
X26
X27
X29
X30
X31
Y1
Y2
R242, R243, R244, R245,
R246
R167, R168, R171, R172
R173, R174, R175, R217
R176, R211
R177
R178, R212
R185, R189
R186, R187
R197, R199, R200, R201
R198, R204
R203, R205
R213
R215
R216, R218
R219
R23, R54
R28, R31, R45, R48
R29, R32, R46, R49,
R138, R139, R140, R141
R33, R34, R165
R40, R60
R56, R68
R57, R84, R86, R91,
R119, R134, R154, R169,
R170
R70, R94, R125, R142
R72, R95
R73, R96, R111, R112
R75, R76, R77, R78, R79,
R80, R81, R153, R155,
R156, R157, R158, R160,
R161
R90
R93, R98, R145, R146
R97, R123, R131, R143,
R147
R99, R100, R101, R102,
R103, R104, R126, R127
R105
R106, R207, R208
R107, R132, R133, R206,
R209, R210
R108, R221
R115, R116, R252, R253,
R254, R255
R118, R120, R121, R135
R124, R152
R128, R159, R162, R163,
R164, R202
R129, R130, R214
R136
R148, R149
R166, R223, R224, R225,
R226, R227, R228, R229,
R230, R231, R232, R233,
R234, R235, R236, R237,
R238, R239, R240, R241,
17
6
5
2
4
8
3
2
2
9
4
2
4
14
1
4
5
8
1
3
6
2
6
4
2
6
3
1
2
25
1
4
2
1
1
1
2
2
1
3
4
1
2
4
2
2
2
1
4
4
8
1
1
1
1
1
1
1
1
1
1
1
1
1
1
3
1
S25012-4752SMT RESISTOR,SMD,METAL FILM,1/16W,47.5K,1%,S0603
S25001-5110SMT RESISTOR,SMD,511OHMS,1/4W,1206,1%,TR
S25001-1501SMT RESISTOR,SMD,1.5K,1/4W,1206,1%,TR
S25001-2210SMT RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
S25001-1002SMT RESISTOR,SMD,10K,1/4W,1206,1%,TR
S25001-4750SMT RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR
S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
S25000-1821SMT RESISTOR,SMD,METAL FILM,1/10W,1.82K,1%,S0805
S25000-1001SMT RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805
S25000-1002SMT RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805
S25012-4751SMT RESISTOR,SMD,METAL FILM,1/16W,4.75K,1%,S0603
S25012-2671SMT RESISTOR,SMD,METAL FILM,1/16W,2.67K,1%,S0603
S25000-2431SMT RESISTOR,SMD,METAL FILM,1/10W,2.43K,1%,S0805
S25001-15R0SMT RESISTOR,SMD,15.0OHMS,1/4W,1206,1%,TR
S25000-2212SMT RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
S25012-1503SMT RESISTOR,SMD,METAL FILM,1/16W,150K,1%,S0603
S25012-1000SMT RESISTOR,SMD,METAL FILM,1/16W,100OHMS,1%,S0603
S25001-26R7SMT RESISTOR,SMD,26.7OHMS,1/4W,1206,1%,TR
S25000-5622SMT RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805
S25000-3322SMT RESISTOR,SMD,METAL FILM,1/10W,33.2K,1%,S0805
S25001-2211SMT RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
S25000-2672SMT RESISTOR,SMD,METAL FILM,1/10W,26.7K,1%,S0805
S25012-1002SMT RESISTOR,SMD,METAL FILM,1/16W,10.0K,1%,S0603
S25012-1501SMT RESISTOR,SMD,METAL FILM,1/16W,1.50K,1%,S0603
S25012-1212SMT RESISTOR,SMD,METAL FILM,1/16W,12.1K,1%,S0603
S25001-1503SMT RESISTOR,SMD,150K,1/4W,1206,1%,TR
S25001-1001SMT RESISTOR,SMD,1K,1/4W,1206,1%,TR
S25000-1500SMT RESISTOR,SMD,METAL FILM,1/10W,150OHMS,1%,S0805
S25000-2801SMT RESISTOR,SMD,METAL FILM,1/10W,2.80K,1%,S0805
S25001-2213SMT RESISTOR,SMD,221K,1/4W,1206,1%,TR
S25000-47R5SMT RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
S25001-2001SMT RESISTOR,SMD,2K,1/4W,1206,1%,TR
S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
S25012-2212SMT RESISTOR,SMD,METAL FILM,1/16W,22.1K,1%,S0603
S25006-10R0SMT RESISTOR,SMD,METAL FILM,1/2W,10OHMS,1%,S2010
S25012-5111SMT RESISTOR,SMD,METAL FILM,1/16W,5.11K,1%,S0603
S25001-1211SMT RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
S25012-1213SMT RESISTOR,SMD,METAL FILM,1/16W,121K,1%,S0603
S25012-1502SMT RESISTOR,SMD,METAL FILM,1/16W,15.0K,1%,S0603
S25001-1213SMT RESISTOR,SMD,121K,1/4W,1206,1%,TR
S25001-3321SMT RESISTOR,SMD,3.32K,1/4W,1206,1%,TR
S25000-4753SMT RESISTOR,SMD,METAL FILM,1/10W,475K,1%,S0805
S25000-5111SMT RESISTOR,SMD,METAL FILM,1/10W,5.11K,1%,S0805
S25000-3922SMT RESISTOR,SMD,METAL FILM,1/10W,39.2K,1%,S0805
S25000-6811SMT RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
S25000-2210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
S25000-2670SMT RESISTOR,SMD,METAL FILM,1/10W,267OHMS,1%,S0805
S13000-123 TRANSFORMER,GATE-DRIVE,PCB,58P60
S20375-40
S15128-28SMT
S15018-21SMT
S25068-40SMT
S25068-6SMT
S25084-5SMT
S25068-12SMT
S25068-39SMT
S15128-11SMT
S25065-5SMT
S25073-27SMT
S25070-26SMT
S25070-35SMT
S20353-4SMT
S25068-38SMT
M15458-15SMT
S25069-17SMT
S25082-9SMT
S25082-11SMT
TRANSFORMER,FLYBACK,AF5175
IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
IC,SMD,CMOS,DRIVER,MOSFET,4451, SOIC-8(SS)
IC,SMD,DRIVER,DUAL,LOW-SIDE,4424YM,SOIC-8(SS)
IC,SMD,VOLT REG,FIXED,3-T,(+),0.1A,5V,SOIC-8
TEMPERATURE SENSOR,SMD,TMP20
IC,SMD,VOLTAGE REGULATOR,3A,+5V,SO8
IC,SMD,VOLTAGE REGULATOR,DUAL OUTPUT,TPS70102
IC,SMD,COMPARATOR,QUAD,2901D
IC,SMD,CMOS,INVERTER,SCHMITT,SINGLE(SS)
IC,SMD,CMOS,DSP,32-BIT,176-PIN,PQFP,TMS320F28235(SS)
IC,SMD,CMOS,CPLD,EPM570T100I5(SS)
IC,SMD,CMOS,ISOLATOR,DIGITAL,2201(SS)
IC,SMD,CMOS,XCVR,EIA485(SS)
IC,SMD,CMOS,DRIVER,MOSFET,2213S,SOIC-16(SS)
IC,SMD,PWM-CONTROLLER,I-MODE,28C44D,SOIC-8
IC,SMD,CMOS,EEPROM,SERIAL,SPI,16KX8,2.7V,SOIC-8
OSCILLATOR,SMD,20.000MHZ
CRYSTAL,SMD,30MHZ
ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
APPLICABLE DRAWING INFORMATION INDEX
PAGE 1
PAGE 2
PRODUCTION DRAWING
PRODUCTION DRAWING
M23003-26 SLIDE LINE WORK INSTRUCTIONS
M23003-27 PROGRAMMING INSTRUCTIONS
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE
CONTROL:
DRAWN BY:
CLEVELAND tsado
DO NOT SCALE THIS DRAWING
ENGINEER:
APPROVED:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
LLUO
GWM
SCALE:
SEE ABOVE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF APPROVAL
DATE:
POWER WAVE S500
PFC CONTROL PC BOARD ASSEMBLY
1/12/2013
PROJECT
NUMBER:
CRM46440
REFERENCE:
-
DOCUMENT
NUMBER:
G6860-1
DOCUMENT
REVISION:
D
G-9
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Power Wave ® S500
G-10
PFC CONTROL BOARD ASSEMBLY (G6860-1 PG 2)
-1 60 G68
ENGINEERING CONTROLLED
MANUFACTURER: Yes
CHANGE DETAIL: ADDED TABLE AND NOTES PER TABLE. REVISED NOTE N.E.1
ELECTRICAL DIAGRAMS G-10
X26
J23A
Q9
X1
Q2
C13
X13
C16
D5 D6
X2
C1
X8
C14
X14
FTP26
FTP15
X21
Q3
D49
OCI1
D26
FTP21
X31
OCI5
X27
FTP17
DZ19
X9
DZ20
FTP29
D7
X3
OCI2
D27
Y2
C4
FTP9
D9
C5
D10
X4
T1
C6
FTP7
D11
C7
FTP8
D12 X5
D18
J23B
D19 D20
X6
C10
X12
Q1
X7
Q10
C20
X18 X19 X17 X16
D28
R257
OCI3
D29
OCI4
J2
1
FTP5
LED2
LED5
X20
1 J1
FTP6
FTP38
X10
FTP12
FTP11
FTP2
D36 D33 D35 D38 D34 D37
C29
D56
D57
C30
FTP40
D62
X24
LED1
Q8
X25
D51
C31
X29 X30 Q7
D61
C32
D67 D66
C33
Q6
C34
G6860-1
D69
R212
FTP3
R83
R211
R140
R141
SCALE = 2:1
PROPRIETARY & CONFIDENTIAL:
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE:
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" ") TO AGREE
DO NOT SCALE THIS DRAWING
CONTROL:
DRAWN BY:
ENGINEER:
CLEVELAND
APPROVED: tsado
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
LLUO
GWM
SCALE:
SEE ABOVE
IF PRINTED
@ A1 SIZE
UNITS:
INCH
EQUIPMENT TYPE:
SUBJECT:
MATERIAL
DISPOSITION:
UF
APPROVAL
DATE:
POWER WAVE S500
PFC CONTROL PC BOARD ASSEMBLY
1/12/2013
PROJECT
NUMBER:
CRM46440
REFERENCE:
-
DOCUMENT
NUMBER:
G6860-1
DOCUMENT
REVISION:
D
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.
This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
Power Wave ® S500

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Advanced waveform control for precise welding on a variety of materials
- User-friendly interface with intuitive controls for ease of use
- Rugged construction for durability in harsh environments
- Lightweight and portable for easy maneuverability
- Versatile operation with multiple welding processes, including MIG, TIG, and Stick
- Digital display for real-time monitoring of welding parameters