Power Wave s500

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POWER WAVE ® S500

For use with machines having Code Numbers:
11813
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SERVICE MANUAL
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SVM239-A | Issue Date 13-Oct

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i SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects and other reproductive harm. cancer, birth defects or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
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 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. 2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
idler by pushing on the throttle control rods

while the engine is running.
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 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
POWER WAVE® S500

ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven-
(earth) ground. tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
3.f. Maintain the electrode holder, work clamp, welding cable and cautions are also required when welding on galvanized
welding machine in good, safe operating condition. Replace steel.
damaged insulation.
5.b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
3.g. Never dip the electrode in water for cooling.
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-

3.h. Never simultaneously touch electrically “hot” parts of
sure level should be checked upon installation and periodi-
electrode holders connected to two welders because voltage
cally thereafter to be certain it is within applicable OSHA PEL
between the two can be the total of the open circuit voltage
and ACGIH TLV limits.
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
3.i. When working above floor level, use a safety belt to protect
coming from degreasing, cleaning or spraying operations.
yourself from a fall should you get a shock.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas and other irritating prod-
3.j. Also see Items 6.c. and 8.
ucts.
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 manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employ-
erʼs 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 SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

explosion. 7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.If process used and properly operating
this is not possible, cover them to prevent the welding sparks regulators designed for the gas and
from starting a fire. Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available. 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 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks or flame.
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard. 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 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. 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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing through 8.b. Install equipment in accordance with the U.S. National
lifting chains, crane cables or other alternate circuits. This can Electrical Code, all local codes and the manufacturerʼs
create fire hazards or overheat lifting chains or cables until recommendations.
they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturerʼs 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 iv
6. Eloigner les matériaux inflammables ou les recouvrir afin de

PRÉCAUTIONS DE SÛRETÉ
prévenir tout risque dʼincendie dû aux étincelles.

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un
antes: échauffement et un risque dʼincendie.
Sûreté Pour Soudage A LʼArc 8. Sʼassurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique: la zone de travail quʼil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dʼautres endroits
a. Les circuits à lʼélectrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans risques dʼincendie ou dʼechauffement des chaines et des
trous pour isoler les mains. câbles jusquʼà ce quʼils se rompent.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse. produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc- 10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement. dʼopérations de dégraissage, nettoyage ou pistolage. La
d. Ne jamais plonger le porte-électrode dans lʼeau pour le chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
refroidir. du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES À SOUDER À
enrouler le câble-électrode autour de nʼimporte quelle partie du
corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
quʼun verre blanc afin de se protéger les yeux du rayon- lʼélectricité et aux recommendations du fabricant. Le dispositif
nement de lʼarc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde lʼarc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de lʻarc. 2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
c. Protéger lʼautre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à lʼaide dʼécrans appropriés et non-inflammables.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de lʼarc de er à lʼinterrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
talons 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 lʼon pique le laitier.
POWER WAVE® S500

Return to Master TOC v SAFETY v
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 manufacturerʼs
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 com-
plete 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 equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems 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

Return to Master TOC vi SAFETY vi
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 manufacturerʼs recommen-
dations. 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 manufacturerʼs recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment 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 manufacturerʼs 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 con-
nection 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 capaci-
tance, 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 applica-
tions. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
POWER WAVE® S500

I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I
RETURN TO MAIN INDEX
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
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

Return to Master TOC 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 A-2
TECHNICAL SPECIFICATIONS - POWER WAVE® S500

Return to Section TOC
POWER SOURCE-INPUT VOLTAGE AND CURRENT

MODEL DUTY INPUT VOLTAGE ± 10% INPUT AMPERES IDLE POWER POWER FACTOR
CYCLE @ RATED OUTPUT
K2904-1 40% rating 208/230/400*460/575 80/73/41/37/29 500 Watts Max. .95
50/60 Hz (fan on)
100% rating 60/54/30/27/21
(includes 380V to 413V)
RATED OUTPUT
INPUT GMAW SMAW GTAW-DC
VOLTAGE/PHASE/
FREQUENCY 40% 60% 100% 40% 60% 100% 40% 60% 100%
200-208/3/50/60 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps
41.5 Volts 39 Volts 36.5 Volts 42 Volts 40 Volts 38 Volts 32 Volts 30 Volts 28 Volts
230/3/50/60
380-415/3/50/60
460/3/50/60
575/3/50/60
RECOMMENDED INPUT WIRE AND FUSE SIZES1
INPUT VOLTAGE/PHASE/ MAXIMUM INPUT AMPERE CORD SIZE 3 AWG TIME DELAY FUSE OR
FREQUENCY RATING AND DUTY CYCLE SIZES (mm2) BREAKER 2 AMPERAGE
200-208/3/50/60 80A, 40% 2 (35) 100
230/3/50/60 73A, 40% 2 (35) 90
380-415/3/50/60 41A, 40% 6 (13) 60
460/3/50/60 37A, 40% 6 (13) 45
575/3/50/60 29A, 40% 8 (10) 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

WELDING PROCESS
PROCESS OUTPUT RANGE (AMPERES) OCV (Uo)

Mean Peak
GMAW 40-550A 60V 100V
GMAW-Pulse
FCAW
GTAW-DC 5-550A 24V
SMAW 15-550A 60V
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT
K2904-1 22.45 in. (570 mm) 14.00 in. (356 mm) 24.08 in. (630 mm) 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

SAFETY PRECAUTIONS WARNING

Read this entire installation section before you

start installation. FALLING EQUIPMENT can
WARNING cause injury.
• Lift only with equipment of ade-
ELECTRIC SHOCK can kill. quate lifting capacity.
• Be sure machine is stable when lifting.
• Only qualified personnel should
perform this installation. • Do not operate machine while suspended when
lifting.
• Turn the input power OFF at the disconnect
switch or fuse box before working on this equip- ------------------------------------------------------------------------
ment. Turn off the input power to any other equip-
ment connected to the welding system at the dis-
STACKING
connect switch or fuse box before working on the The Power Wave® S500 cannot be stacked.
equipment.
TILTING
• Do not touch electrically hot parts.

Place the machine directly on a secure, level surface
• Always connect the Power Wave® S500 grounding
or on a recommended undercarriage. The machine
lug to a proper safety (Earth) ground.
may topple over if this procedure is not followed.
------------------------------------------------------------------------
INPUT AND GROUND CONNEC-
SELECT SUITABLE LOCATION TIONS
The Power Wave® S500 will operate in harsh environ- Only a qualified electrician should connect the Power
ments. Even so, it is important that simple preventative Wave® S500. Installation should be made in accor-
measures are followed in order to assure long life and dance with the appropriate National Electrical Code, all
reliable operation. local codes and the information in this manual.
• The machine must be located where there is circula- MACHINE GROUNDING
tion of clean air.
The frame of the welder must be grounded. A ground
• Dirt and dust that can be drawn into the machine terminal marked with a ground symbol is located next
should be kept to a minimum. The use of air filters on to the input power connection block.
the air intake is not recommended because normal
air flow may be restricted. Failure to observe these See your local and national electrical codes for proper
precautions can result in excessive operating tem- grounding methods.
peratures and nuisance shutdown.
HIGH FREQUENCY PROTECTION
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles. Locate the Power Wave® S500 away from radio con-
trolled machinery. The normal operation of the Power
• Do not mount the Power Wave® S500 over com- Wave® S500 may adversely affect the operation of RF
bustible surfaces. Where there is a combustible sur- controlled equipment, which may result in bodily injury
face directly under stationary or fixed electrical equip- or damage to the equipment.
ment, 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
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 acces-
sories attached to it.
POWER WAVE® S500

WARNING INPUT FUSE AND SUPPLY WIRE

CONSIDERATIONS
Only a qualified electrician should connect the See Technical Specifications for recommended fuse,
input leads to the Power Wave® S500. Connections wire sizes and type of the copper wires. Fuse the input
should be made in accordance with all local and circuit with the recommended super lag fuse or delay
national electrical codes and the connection dia- type breakers (also called "inverse time" or "ther-
grams. Failure to do so may result in bodily injury mal/magnetic" circuit breakers). Choose input and
or death. grounding wire size according to local or national elec-
------------------------------------------------------------------------ trical codes. Using input wire sizes, fuses or circuit
breakers smaller than recommended may result in
INPUT CONNECTION "nuisance" shut-offs from welder inrush currents, even
if the machine is not being used at high currents.
(See Figure A.1)
Use a three-phrase supply line. A 1.40 inch diameter
INPUT VOLTAGE SELECTION
access hole with strain relief is located on the case The Power Wave® S500 automatically adjusts to work
back. Route input power cable through this hole and with different input voltages. No reconnect switch set-
connect L1, L2, L3 and ground per connection dia- tings are required.
grams and National Electric Code. To access the input
power connection block, remove three screws holding WARNING
the access door to the side of the machine.
ALWAYS CONNECT THE POWER WAVE GROUND- The Power Wave® S500 ON/OFF
ING LUG (LOCATED AS SHOWN IN FIGURE A.1) TO switch is not intended as a service
A PROPER SAFETY (EARTH) GROUND. disconnect for this equipment. Only
a qualified electrician should con-
nect the input leads to the Power
Wave® S500. Connections should be
made in accordance with all local
and national electrical codes and
the connection diagram 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
GROUND CONNECTION
CONNECT GROUND LEAD PER LOCAL
AND NATIONAL ELECTRIC CODE
INPUT CORD STRAIN RELIEF

ROUTE INPUT CORD POWER CONNECTION BLOCK
THROUGH RELIEF AND CONNECT EACH PHASE OF A THREE-PHASE
TWIST NUT TO TIGHTEN CONDUCTOR HERE
INPUT POWER
ACCESS DOOR
POWER WAVE® S500

CONNECTION DIAGRAMS
GTAW (TIG) WELDING

A user interface is required for adjusting the TIG weld-
ing settings. S-series user interface (K3001-2) can be
installed into the power source (Figure A.2). Refer to
the connection diagrams based on the user interface
that is being used. Alternate configurations are possi-
ble depending on the wire feeder that is being used.
Refer to the wire feederʼs manual for alternative con-
figurations.
FIGURE A.2
REGULATOR
FLOWMETER
TIG WITH S-SERIES USER INTERFACE
USE
SER IINTERFACE
CONTROL PAPANEL
K30
3001
01-2
TO REMOTE CONTROL
RECEP
EPTACLE
GAS HOSE
GAS SOLENOID KIT

(INSIDE MACH
CHINE)
K282
825-1 FOOT AMPTROL
870
K87
TO POSITIVE
VE (+) STUD
TO NEGATIVE
VE (-) STUD
WORK CLAMP
WORK PIECE
TIG TORC
RCH
K2266-1 KIT
(INC
NCLUD
UDES
ES W ORK CLAMP,
ADAP
APTER, AND REGULATOR)
POWER WAVE® S500

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 dia-
gram 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

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

GMAW (MIG) WELDING

An arclink compatible wire feeder is recommended for

Mig welding. See Figure A.4 for the connection details.
FIGURE A4
REGULATOR MIG PROCESS

FLOWMETER
GAS
AS HOSE
ARC
RCLINK CABLE
K1543-[XX] TO NEGATIVE
VE (-) STUD
WORK CLAMP
TO POSITIVE
VE (+) STUD
WORK PIECE
PF10
10-M
WIRE F
FEE
EEDER
POWER WAVE® S500

RECOMMENDED WORK CABLE GENERAL GUIDELINES

SIZES FOR ARC WELDING • Select the appropriate size cables per the “Output
Cable Guidelines” below. Excessive voltage drops
Connect the electrode and work cables between the
caused by undersized welding cables and poor con-
appropriate output studs of the Power Wave® S500 per
nections often result in unsatisfactory welding perfor-
the following guidelines:
mance. Always use the largest welding cables (elec-
• Most welding applications run with the electrode trode and work) that are practical and be sure all con-
being positive (+). For those applications, connect the nections are clean and tight.
electrode cable between the wire drive feed plate and
NOTE: Excessive heat in the weld circuit indicates
the positive (+) output stud on the power source.
undersized cables and/or bad connections.
Connect a work lead from the negative (-) power
source output stud to the work piece. • Route all cables directly to the work and wire
feeder, avoid excessive lengths and do not coil
• When negative electrode polarity is required, such as
excess cable. Route the electrode and work cables
in some Innershield applications, reverse the output
in close proximity to one another to minimize the loop
connections at the power source (electrode cable to
area and therefore the inductance of the weld circuit.
the negative (-) stud and work cable to the positive (+)
stud). • Always weld in a direction away from the work

(ground) connection.
CAUTION Table A.1 shows copper cable sizes recommended for
different currents and duty cycles. Lengths stipulated
Negative electrode polarity operation WITHOUT are the distance from the welder to work and back to
use of a remote work sense lead (21) requires the the welder again. Cable sizes are increased for
Negative Electrode Polarity attribute to be set. See greater lengths primarily for the purpose of minimizing
the Remote Sense Lead Specification section of cable drop.
this document for further details.
------------------------------------------------------------------------
For additional Safety information regarding the elec-
trode and work cable set-up, See the standard Safety
Information located in the front of this Service
Manual.
TABLE A.1 – OUTPUT CABLE GUIDELINES

Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
Amperes Cycle 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

CABLE INDUCTANCE AND ITS REMOTE SENSE LEAD SPECIFICA-

EFFECTS ON WELDING TIONS

Excessive cable inductance will cause the welding per- VOLTAGE SENSING OVERVIEW
formance to degrade. There are several factors that The best arc performance occurs when the Power
contribute to the overall inductance of the cabling sys- Wave® S500 has accurate data about the arc condi-
tem including cable size and loop area. The loop area tions.
is defined by the separation distance between the elec-
trode and work cables and the overall welding loop Depending upon the process, inductance within the
length. The welding loop length is defined as the total electrode and work cables can influence the voltage
of length of the electrode cable (A) + work cable (B) + apparent at the studs of the welder and have a dra-
work path (C) (See Figure A.5). matic effect on performance. Remote voltage sense
leads are used to improve the accuracy of the arc volt-
To minimize inductance always use the appropriate age information supplied to the control pc board.
size cables and whenever possible, run the electrode Sense Lead Kits (K940-xx) are available for this pur-
and work cables in close proximity to one another to pose.
minimize the loop area. Since the most significant fac-
tor in cable inductance is the welding loop length, avoid The Power Wave® S500 has the ability to automatical-
excessive lengths and do not coil excess cable. For ly sense when remote sense leads are connected.
long work piece lengths, a sliding ground should be With this feature there are no requirements for setting-
considered to keep the total welding loop length as up the machine to use remote sense leads. This fea-
short as possible. ture can be disabled through the Weld Manager Utility
(available at www.powerwavesoftware.com) or
through the set up menu (if a user interface is installed
into the power source).
CAUTION
If the auto sense lead feature is disabled and
remote voltage sensing is enabled but the sense
leads are missing or improperly connected
extremely high welding outputs may occur.
------------------------------------------------------------------------
TABLE A.2
Process Electrode Voltage Sensing (1) Work Voltage Sensing (2)

67 lead 21 lead
GMAW 67 lead required 21 lead optional (3)

GMAW-P 67 lead required 21 lead optional (3)
FCAW 67 lead required 21 lead optional (3)
GTAW Voltage sense at studs Voltage sense at studs
SMAW 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
WORK
B
POWER WAVE® S500

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 pos-
sible. In extremely sensitive applications it may be nec-
essary 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 pre-
sent. 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 sens-
ing 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 automatical-
ly sense the polarity of the sense leads. With this fea-
ture there are no set-up requirements for welding with
negative electrode polarity. This feature can be dis-
abled 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

VOLTAGE SENSING If Sense Leads ARE Used:

CONSIDERATIONS FOR MULTIPLE • Position the sense leads out of the path of the weld
current. Especially any current paths common to
ARC SYSTEMS adjacent arcs. Current from adjacent arcs can induce
Special care must be taken when more than one arc is voltage into each others current paths that can be
welding simultaneously on a single part. Multiple arc misinterpreted by the power sources and result in arc
applications do not necessarily dictate the use of interference.
remote work voltage sense leads, but they are strong- • For longitudinal applications, connect all work leads
ly recommended. at one end of the weldment and all of the work volt-
If Sense Leads ARE NOT Used: age sense leads at the opposite end of the weldment.
Perform welding in the direction away from the work
• Avoid common current paths. Current from adjacent leads and toward the sense leads. See Figure A.6.
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
CONNECT ALL SENSE

LEADS AT THE END
DIRECTION OF THE WELD.
OF TRAVEL
CONNECT ALL
WORK LEADS AT
THE BEGINNING
OF THE WELD.
POWER WAVE® S500

• For circumferential applications, connect all work

leads on one side of the weld joint and all of the work
voltage sense leads on the opposite side, such that
they are out of the current path. See Figure A.7.
FIGURE A.7
POWER
SOURCE
#1
POWER
SOURCE
#2
POWER
POWER SOURCE
SOURCE #2
#1
POWER
SOURCE
#1
POWER
SOURCE
#2
POWER WAVE® S500

CONTROL CABLE CONNECTIONS CONNECTION BETWEEN POWER

SOURCE AND ETHERNET NETWORKS

GENERAL GUIDELINES The Power Wave® S500 is equipped with an IP67 rated
ODVA compliant RJ-45 Ethernet connector, which is
Genuine Lincoln control cables should be used at all
located on the rear panel. All external Ethernet equip-
times (except where noted otherwise). Lincoln cables
ment (cables, switches, etc.), as defined by the con-
are specifically designed for the communication and
nection diagrams, must be supplied by the customer. It
power needs of the Power Wave® / Power Feed™ sys-
is critical that all Ethernet cables external to either a
tems. Most are designed to be connected end to end
conduit or an enclosure are solid conductor, shielded
for ease of extension. Generally, it is recommended
cat 5e cable, with a drain. The drain should be ground-
that the total length not exceed 100ft. (30.5m). The use
ed at the source of transmission. For best results, route
of non-standard cables, especially in lengths greater
Ethernet cables away from weld cables, wire drive con-
than 25 feet, can lead to communication problems
trol cables or any other current carrying device that can
(system shutdowns), poor motor acceleration (poor arc
create a fluctuating magnetic field. For additional
starting) and low wire driving force (wire feeding prob-
guidelines refer to ISO/IEC 11801. Failure to follow
lems). Always use the shortest length of control cable
these recommendations can result in an Ethernet con-
possible and DO NOT coil excess cable.
nection 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 inter-
ference between the high currents flowing through the
weld cables and the low level signals in the control
cables. These recommendations apply to all communi-
cation cables including ArcLink® and Ethernet connec-
tions.
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 communi-
cation and one lead for voltage sensing. The 5-pin
ArcLink connection on the Power Wave® S500 is locat-
ed 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 sepa-
rate 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

Return to Master TOC 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 OPERATION B-2
SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

READ AND UNDERSTAND ENTIRE SECTION
BEFORE OPERATING MACHINE.
WARNING OR
WARNING
CAUTION
ELECTRIC SHOCK can kill.
• Do not touch electrically live part
DANGEROUS
or electrode with skin or wet cloth- VOLTAGE
ing.
• Insulate yourself from work and ground.
POSITIVE OUTPUT
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards
removed or open. NEGATIVE OUTPUT
------------------------------------------------------------------------
FUMES AND GASSES can be
dangerous. HIGH TEMPERATURE
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing STATUS
zone.
------------------------------------------------------------------------
PROTECTIVE
WELDING SPARKS can cause GROUND
fire or explosion.
• Keep flammable material away.
------------------------------------------------------------------------ COOLER
ARC RAYS can burn.

• Wear eye, ear and body protection.
------------------------------------------------------------------------ OUTPUT
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS OPERATORS
AND in the FRONT OF THIS OPERATING MANUAL.
MANUAL
------------------------------------------------------------------------
POWER-UP SEQUENCE
WORK
When the Power Wave® S500 is powered up, it can
take as long as 30 seconds for the machine to be
ready to weld. During this time period the user inter-
face will not be active. CIRCUIT BREAKER
DUTY CYCLE
The duty cycle is based on a ten-minute period. A 40%

duty cycle represents 4 minutes of welding and 6 min-
utes of idling in a ten-minute period. See the
Technical Specification section for the Power Wave®
S500ʼs duty cycle ratings.
POWER WAVE® S500

B-3 OPERATION B-3
PRODUCT DESCRIPTION RECOMMENDED EQUIPMENT

The Power Wave® S500 is designed to be compatible

PRODUCT SUMMARY with the current range of Power Feed™ systems
including future versions of ArcLink® feeders.
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 weld- RECOMMENDED PROCESSES
ing. It is ideal for a wide variety of materials including The Power Wave® S500 is a high speed, multi-process
aluminum, stainless and nickel — where arc perfor- power source capable of regulating the current, volt-
mance is critical. age or power of the welding arc. With an output range
The Power Wave® S500 is designed to be a very flexi- of 5 to 550 amperes, it supports a number of standard
ble welding system. Like existing Power Waveʼs®, the processes including synergic GMAW, GMAW-P,
software based architecture allows for future upgrade- FCAW, FCAW-SS, SMAW, GTAW and GTAW-P on
ability. One significant change from the current range various materials especially steel, aluminum and stain-
of Power Wave® units is that the Ethernet communica- less.
tion feature is standard on the Power Wave® S500
which allows for effortless software upgrades through PROCESS LIMITATIONS
Powerwavesoftware.com. The Ethernet communica-

tion also gives the Power Wave® S500 the ability to run The software based weld tables of the Power Wave®
Production Monitoring™ 2. A Devicenet option allows S500 limit the process capability within the output
the Power Wave® S500 to be used in a wide range of range and the safe limits of the machine. In general the
configurations and the Power Wave® S500 is designed processes will be limited to .030 - .052 solid steel wire,
to be compatible with advanced welding modules like .030 - .045 stainless wire, .035 - 1/16 cored wire and
STT. .035 - 1/16 Aluminum wire.
RECOMMENDED PROCESSES AND EQUIPMENT LIMITATIONS

EQUIPMENT Only ArcLink compatible semiautomatic wire feeders
and users interfaces may be used. If other Lincoln wire
The Power Wave® S500 is recommended for semiau- feeders or non-Lincoln wire feeders are used there will
tomatic welding and may also be suitable for basic be limited process capability and performance and fea-
hard automation applications. The Power Wave® S500 tures will be limited.
can be set up in a number of configurations, some
requiring optional equipment or welding programs.
POWER WAVE® S500

B-4 OPERATION B-4
DESIGN FEATURES CASE FRONT CONTROLS

See Figure B.1

LOADED WITH STANDARD FEATURES
1. USER INTERFACE (optional)
• Multiple process DC output range: 5 - 550 Amps.
2. STATUS LED - (See Troubleshooting section for
• 200 – 600 VAC, 3 phase, 50-60Hz input power. operational functions)
• New and Improved Line Voltage Compensation holds 3. THERMAL LED - Indicates when machine has ther-
the output constant over wide input voltage fluctua- mal fault.
tions.
4. POWER SWITCH - Controls power to the Power
• Utilizes next generation microprocessor control, Wave® S500.
based on the ArcLink® platform.
5. NEGATIVE WELD OUTPUT
• State of the art power electronics technology yields
superior welding capability. 6. POSITIVE WELD OUTPUT
• Electronic over current protection. 7. WORK SENSE LEAD CONNECTOR

8. 12-PIN CONNECTOR (Optional)
• Input over voltage protection.

• F.A.N. (fan as needed). Cooling fan only runs when FIGURE B.1
needed.
• Thermostatically protected for safety and reliability.
• Ethernet connectivity.
• Panel mounted Status and Thermal LED indicators 1
facilitate quick and easy troubleshooting.
• Potted PC boards for enhanced ruggedness/reliabili-
ty.
2
• Enclosure reinforced with heavy duty aluminum
extrusions for mechanical toughness. 3
• Waveform Control Technology™ for good weld
appearance and low spatter, even when welding nick-
4
el alloys.
• Sync Tandem installed.
5 6 7 8
POWER WAVE® S500

B-5 OPERATION B-5
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
1
7
2
5 10
6
POWER WAVE® S500

B-6 OPERATION B-6
COMMON WELDING PROCEDURES BASIC WELDING CONTROLS

WARNING WELD MODE

MAKING A WELD Selecting a weld mode determines the output charac-
The serviceability of a product or structure utiliz- teristics of the Power Wave® power source. Weld
ing the welding programs is and must be the sole modes are developed with a specific electrode materi-
responsibility of the builder/user. Many variables al, electrode size and shielding gas. For a more com-
beyond the control of The Lincoln Electric plete description of the weld modes programmed into
Company affect the results obtained in applying the Power Wave® S500 at the factory, refer to the Weld
these programs. These variables include, but are Set Reference Guide supplied with the machine or
not limited to, welding procedure, plate chemistry available at www.powerwavesoftware.com.
and temperature, weldment design, fabrication
methods and service requirements. The available WIRE FEED SPEED (WFS)
range of a welding program may not be suitable
for all applications and the build/user is and must In synergic welding modes (synergic CV, GMAW-P),
be solely responsible for welding program selec- WFS is the dominant control parameter. The user
tion. adjusts WFS according to factors such as wire size,

penetration requirements, heat input, etc. The Power
Choose the electrode material, electrode size, shield- Wave® S500 then uses the WFS setting to adjust the
ing gas and process (GMAW, GMAW-P etc.) appropri- voltage and current according to settings contained in
ate for the material to be welded. the POWER WAVE®.
Select the weld mode that best matches the desired In non-synergic modes, the WFS control behaves like
welding process. The standard weld set shipped with a conventional power source where WFS and voltage
the Power Wave® S500 encompasses a wide range of are independent adjustments. Therefore, to maintain
common processes that will meet most needs. If a proper arc characteristics, the operator must adjust the
special weld mode is desired, contact a local Lincoln voltage to compensate for any changes made to the
Electric sales representative. WFS.
All adjustments are made through the user interface.
Because of the different configuration options your AMPS
system may not have all of the following adjustments.
In constant current modes, this control adjusts the
See Accessories section for Kits and Options avail- welding amperage.
able to use with the Power Wave® S500.
DEFINITION OF WELDING MODES VOLTS

In constant voltage modes, this control adjusts the
NON-SYNERGIC WELDING MODES welding voltage.
• A Non-synergic welding mode requires all welding

process variables to be set by the operator. TRIM
In pulse synergic welding modes, the Trim setting
SYNERGIC WELDING MODES adjusts the arc length. Trim is adjustable from 0.50 to
1.50. 1.00 is the nominal setting and is a good starting
• A Synergic welding mode offers the simplicity of sin- point for most conditions.
gle knob control. The machine will select the correct
voltage and amperage based on the Wire Feed
Speed (WFS) set by the operator. 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 OPERATION B-7
SMAW (STICK) WELDING The nominal preprogrammed voltage is the best aver-
age voltage for a given wire feed speed, but may be

The welding current and Arc Force settings can be set adjusted to preference. When the wire feed speed
through a Power Feed™ 10M or Power Feed™ 25M changes, the Power Wave® S500 automatically adjusts
wire feeder. Alternatively an optional Stick / Tig UI can the voltage level correspondingly to maintain similar
be installed into the power source to control these set- arc characteristics throughout the WFS range.
tings locally.
In a SMAW (STICK mode), Arc Force can be adjusted. NON SYNERGIC CV
It can be set to the lower range for a soft and less pen-
etrating arc characteristic (negative numeric values) or In non-synergic modes, the WFS control behaves
to the higher range (positive numeric values) for a crisp more like a conventional CV power source where WFS
and more penetrating arc. Normally, when welding with and voltage are independent adjustments. Therefore
cellulosic types of electrodes (E6010, E7010, E6011), to maintain the arc characteristics, the operator must
a higher energy arc is required to maintain arc stabili- adjust the voltage to compensate for any changes
ty. This is usually indicated when the electrode sticks to made to the WFS.
the work-piece or when the arc becomes unstable dur-
ing manipulative technique. For low hydrogen types of ALL CV MODES
electrodes (E7018, E8018, E9018, etc.) a softer arc is

usually desirable and the lower end of the Arc Control Pinch adjusts the apparent inductance of the wave
suits these types of electrodes. In either case the arc shape. The “pinch” function is inversely proportional to
control is available to increase or decrease the energy inductance. Therefore, increasing Pinch Control
level delivered to the arc. 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 PULSE WELDING
Feed™ 10M or Power Feed™ 25M wire feeder.
Alternatively an optional Stick / Tig UI can be installed Pulse welding procedures are set by controlling an
into the power source to control these settings locally. overall “arc length” variable. When pulse welding, the
arc voltage is highly dependent upon the waveform.
The TIG mode features continuous control from 5 to The peak current, back ground current, rise time, fall
550 amps with the use of an optional foot amptrol. The time and pulse frequency all affect the voltage. The
Power Wave® S500 can be run in either a Touch Start exact voltage for a given wire feed speed can only be
TIG mode or Scratch start TIG mode. predicted when all the pulsing waveform parameters
are known. Voltage or Trim can be adjusted.

CONSTANT VOLTAGE WELDING
Trim adjusts the arc length and ranges from 0.50 to
SYNERGIC CV 1.50 with a nominal value of 1.00. Trim values greater
For each wire feed speed, a corresponding voltage is than 1.00 increase the arc length, while values less
preprogrammed into the machine through special soft- than 1.00 decrease the arc length. See Figure B.3.
ware at the factory.
FIGURE B.3
Trim .50 Trim 1.00 Trim 1.50

Arc Length Short Arc Length Medium Arc L ength Long
POWER WAVE® S500

B-8 OPERATION B-8
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 reach-
ing 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 back-
ground 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 UltimArc™ Control OFF UltimArc™ Control +10.0

Low Frequency, Wi de Med ium Fr equency and Wi dth Hi gh Frequency , Fo cu sed
POWER WAVE® S500

Return to Master TOC 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 C-2
KITS, OPTIONS AND ACCESSORIES K1842-10 10ft. Weld Power Cable

All Kits, Options and Accessories are found on the Coaxial Welding Cable
Web site: (www.lincolnelectric.com) 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
Order K1796-100 for 100 feet (30.5 m) cable
Stick / Tig User Interface Kit length.
Mounts inside the front panel of the Power Wave® AWG #1 Coaxial Cables:
S500. Allows stick and Tig operation without having a
wire feeder. Order K2593-25 for 25 feet (7.6 m) cable length.
Order K3001-2
DeviceNet Kit Order K2593-100 for 100 feet (30.5 m) cable

length.
Mounts inside the back of the Power Wave® S500.
Allows Devicenet objects to communicate with the K2909-1
Power Wave® S500. 12-pin to 6-pin adapter.
Order K2827-1 K2910-1
Work Voltage Sense Lead Kit 12-pin to 7-pin adapter.
Required to accurately monitor voltage at the arc. Welding Fume Extractors
Order K940-XX Series Lincoln offers a wide range of fume extraction environ-
Order K1811-XX Series mental system solutions, ranging from portable sys-
tems easily wheeled around a shop to shop-wide cen-
Deluxe Adjustable Gas Regulator & Hose Kit tral systems servicing many dedicated welding sta-
Accommodates CO2, Argon or Argon-blend gas cylin- tions.
ders. Includes a cylinder pressure gauge, dual scale Request Lincoln publication E13.40
flow gauge and 4.3 ft. (1.3 m) gas hose.
(See www.lincolnelectric.com)
Order K586-1
K2149-1 Work Lead Package
POWER WAVE® S500

C-3 ACCESSORIES C-3
STICK OPTIONS TIG-Mate™ 17V Air-Cooled TIG Torch Starter Pack

Get everything you need for TIG welding in one com-

ACCESSORY KIT - 150 Amp plete easy-to-order kit packaged in its own portable
For stick welding. Includes 20 ft. carrying case. Includes: PTA-17V torch, parts kit,
(6.1m) #6 electrode cable with lug, Harris® flowmeter/regulator, 10 ft. (3.0 m) gas hose and
15 ft. (4.6m) #6 work cable with work clamp and cable.
lugs, headshield, filter plate, work Order K2265-1
clamp, electrode holder and sample
pack of mild steel electrode. COMPATIBLE LINCOLN EQUIPMENT
ORDER K875
Any Arclink compatible wire feeding equipment
ACCESSORY KIT - 400 AMP (See www.lincolnelectric.com).
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).
Hand Amptrol®
Provides 25 ft. (7.6 m) of remote cur-

rent 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

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C-4

NOTES
POWER WAVE® S500

C-4
Return to Master TOC 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 D-2
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not operate with covers
removed.
• Turn off power source before
installing or servicing.
• Do not touch electrically hot parts.
• Turn the input power to the welding power source
off at the fuse box before working in the terminal
strip.
• Only qualified personnel should install, use or
service this equipment.
------------------------------------------------------------------------
ROUTINE MAINTENANCE
Routine maintenance consists of periodically blowing
out the machine, using a low-pressure air stream, to
remove accumulated dust and dirt from the intake and
outlet louvers and the cooling channels in the machine.
PERIODIC MAINTENANCE
Calibration of the Power Wave® S500 is critical for reli-
able operation. Generally speaking the calibration will
not need adjustment. However, neglected or improper-
ly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the cali-
bration of output Voltage and Current should be
checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the facto-
ry. Generally, calibration will not need adjustment.
However, if the weld performance changes or the year-
ly calibration check reveals a problem, use the calibra-
tion 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 instruc-
tions and is available at:
www.powerwavesoftware.com.
POWER WAVE® S500

D-3 MAINTENANCE D-3
FIGURE D.1 – MAJOR COMPONENTS LOCATIONS

1. Case Front Assembly

2. Base & Power Conversion Assembly
3. Case Back Assembly
4. Roof Assembly
4
2
POWER WAVE® S500

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-4

NOTES
POWER WAVE® S500

D-4
Return to Master TOC 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
USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
DIGITAL CONTROL BOARD REMOTE
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
POWER CONVERSION PFC BOARD

P.C. BOARD ASSEMBLY
ARCLINK
FAN SPEED RECEPTACLE
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
BUCK-BOOST FULL BRIDGE
MAIN BOARD INVERTER

MULTI-PHASE
INPUT PLANAR OUTPUT CHOKE
TRANSFORMERS
SWITCH RECTIFIED AND

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK
+15VDC BUCK-BOOST FULL BRIDGE

INVERTER OUTPUT CURRENT FEEDBACK
DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
THERMAL 200VAC 115 VAC 115 VAC
FAN RECEPTACLE ARC LINK AND
FAULT P.C. BOARD
CONTROL VOLTAGE SENSE FROM
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

FAST FAULT SIGNAL GAS
CONTROL BOARD DIGITAL CONTROL BOARD SOLENOID
40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS
RJ45 DEVICENET VOLTAGE

CONNECTOR CONNECTOR SENSE
RECEPTACLE
POWER WAVE® S500

E-2 THEORY OF OPERATION E-2
FIGURE E.2 - GENERAL DESCRIPTION

USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
P.C. BOARD ASSEMBLY
ARCLINK
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
MAIN BOARD INVERTER

MULTI-PHASE
TRANSFORMERS

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK

DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
FAULT P.C. BOARD
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS

RECEPTACLE
GENERAL DESCRIPTION
The Power Wave® S500 is a welder featuring an invert-
er type power source with Tribrid Converter
Technology and Automatic PowerConnect Technology.
It is a multi-process machine with high-end functionali-
ty capable of Stick, DC TIG, MIG, Pulsed MIG and
Flux-Cored welding. The Power Wave® S500 regu-

lates 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 architec-
ture 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 semiautomat-
ic welding and may also be suitable for basic hard
automation applications. It is compatible with the cur-
rent 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

FIGURE E.3 - LINE SWITCH, INPUT BOARD AND POWER FACTOR CONTROL (PFC) BOARD
USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
P.C. BOARD ASSEMBLY
ARCLINK
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
MAIN BOARD INVERTER

MULTI-PHASE
TRANSFORMERS

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK

DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
FAULT P.C. BOARD
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS

RECEPTACLE
LINE SWITCH, INPUT BOARD AND

POWER FACTOR CONTROL (PFC)
BOARD
The Power Wave® S500 can be connected to a variety The rectified input power is also connected to the
of both three-phase or single-phase AC input voltages. Power Factor Correction board. The PFC board
The Power Wave® S500 automatically adjusts to oper- receives this unregulated DC voltage and converts it
ate with different AC input voltages. No reconnect to several DC supplies that are used to power the
switch settings are required. The initial input power is electronics housed on the PFC board. A 36VDC sup-
applied through a line switch located on the front panel ply is also connected to the Digital Control Board.
of the machine. This AC input voltage is applied to an
input board where it is rectified to a DC voltage. The The PFC board receives feedback information in the
DC voltage is then applied to a soft-start circuit conform of buck-boost currents, the 400VDC bus voltage,
sisting of two PTC thermistors and two DC relays. This the rectified AC input voltage, the full bridge inverter
soft-start circuit limits the initial inrush current to the DC currents and power module temperatures. The elec-
link capacitors to prevent damage to the input rectifier. tronic circuits and firmware on the PFC board generate
Two seconds after the input line switch is activated the Pulse Width Modulation (PWM) signals to regulate the
two relays, which are in parallel with the thermistors, 400VDC bus, drive the buck-boost circuit, shape the
are closed thus applying the full input potential to the input current, drive the full bridge inverters and control
DC link capacitor. The two DC relays are activated by the pre-charge relays.
the Power Factor Correction board.

POWER WAVE® S500

FIGURE E.4 - POWER CONVERSION BOARD ASSEMBLY

USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
P.C. BOARD ASSEMBLY
ARCLINK
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
MAIN BOARD INVERTER

MULTI-PHASE
TRANSFORMERS

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK

DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
FAULT P.C. BOARD
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS

RECEPTACLE
POWER CONVERSION BOARD

ASSEMBLY
Several circuits are located on the Power Conversion Planar Transformers: The primaries of the two Planar
Board. They are the two interleaved buck-boost con- Transformers are in parallel but are driven 90 degrees
verters, two full-bridge inverters, two planar transform- out of phase with each other. Both transformers have
ers and a fan control circuit. a 100 volt secondary winding for welding power. The
outputs of these 100 volt windings are rectified and
Buck-Boost Converters: The two Buck-Boost con-
coupled to the six Phase Chopper Board. The lower
verters operate at 25 KHz. These converters convert
Planar Transformer has a 200 volt secondary winding
the input voltage to a 400VDC bus. The PFC board
that is used to power the 115VAC inverter board. The
regulates the Buck-Boost circuits to attain a very high
upper Planar Transformer has a 48 volt secondary
power factor. If the rectified input voltage is greater or
winding that is rectified and filtered and is applied to
less than 400VDC, either the “Buck” portion or the
the DC Bus board. The 48VDC is also used to power
“Boost” portion of the circuitry will be active. The two
the fan speed control circuit.
Buck-Boost circuits are driven by separate PWM sig-
nals 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 pro-
vide the inverter switches with a 98% on time. The out-
puts of the Full Bridge Inverters are applied to the pri-
maries of the two Planar Transformers.

POWER WAVE® S500

FIGURE E.5 - SIX PHASE CHOPPER BOARD AND MULTI-PHASE OUTPUT CHOKE
USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
P.C. BOARD ASSEMBLY
ARCLINK
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
MAIN BOARD INVERTER

MULTI-PHASE
TRANSFORMERS

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK

DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
FAULT P.C. BOARD
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS

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 sec-
ondary 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 con-
nected 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 con-
nected to the negative output terminal.

POWER WAVE® S500

FIGURE E.6 - DC BUS BOARD AND DIGITAL CONTROL BOARD

USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
P.C. BOARD ASSEMBLY
ARCLINK
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
MAIN BOARD INVERTER

MULTI-PHASE
TRANSFORMERS

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK

DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
FAULT P.C. BOARD
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS

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 sup-
ply. 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 volt-
age 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 sole-
noid 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.

POWER WAVE® S500

FIGURE E.7 - OPTIONAL REMOTE CONTROL BOARD AND 115VAC INVERTER BOARD
USER INTERFACE
ARCLINK AND
VOLTAGE SENSE TO
CONTROL
REMOTE AMPTROL
FAN FAN BOARD
+
ARCLINK RECEPTACLE
40 VDC TO
P.C. BOARD ASSEMBLY
ARCLINK
TOP PLANAR 40 VDC
CONTROL INPUT
DC
CHOKE
TRANSFORMERS
48 VDC BUS
POWER BOARD
BOARD
OUTPUT
RECTIFIER
400V BUS
+
SIX PHASE
INPUT CHOPPER BOARD
MAIN BOARD INVERTER

MULTI-PHASE
TRANSFORMERS

FILTERED LINE 48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
-
INPUT
CHOKE
200VAC
POWER BOARD
CURRENT
BUCK/BOOST FEEDBACK
OUTPUT
DRIVE RECTIFIER
RELAY 400V BUS

FULL WAVE BRIDGE
FEEDBACK

DRIVES
RELAY CONTROL
DRIVE PLANAR
TRANSFORMERS
RECTIFIED
LINE VOLTAGE
FAULT P.C. BOARD
FAN ON REMOTE BOARD
SIGNAL OUTPUT ON
SIGNAL
POWER FACTOR (PFC)

40VDC FROM 36 VDC
DC BUS BOARD
CAN COMMUNICATIONS

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 communica-
tions 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.

POWER WAVE® S500

MACHINE PROTECTION
THERMAL PROTECTION PROTECTIVE CIRCUITS

Three normally closed (NC) thermostats protect the Protective circuits are designed into the Power Wave®
machine from excessive operating temperatures. Two S500 to sense trouble and shut down the machine
thermostats are located on the 115VAC heat sink and before damage occurs to the machineʼs internal com-
protect the 115VAC Inverter board from over-heating. ponents. Error Codes will be flashed out by the light on
The third thermostat is located and integrated into the the front of the machine and will help identify the rea-
Six Phase Chopper and is monitored by the Digital son for the shutdown. Fault codes can also be seen by
Control board. Excessive temperatures may be using the Diagnostic Software. Various status lights
caused by a lack of cooling air or by operating the located on the PC boards aid in determining compo-
machine beyond its duty cycle or output rating. If nent status and diagnosing problems. See the
excessive operating temperatures should occur, the Troubleshooting section for more information regard-
thermostats will prevent output from the machine. The ing Error Codes.
yellow thermal light, located on the front of the
machine, will be illuminated. The thermostats are self- OVER CURRENT PROTECTION
resetting once the machine cools sufficiently. If the
If the machineʼs welding output is shorted the Digital

thermostat shutdown was caused by excessive output Control board will limit the current to 375 amps.
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.
POWER WAVE® S500

FIGURE E.8 - INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION

POSITIVE
VOLTAGE
APPLIED
GATE GATE
SOURCE SOURCE
n+ n+ n+ n+
p BODY REGION p BODY REGION
n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION
n+ BUFFER LAYER n+ BUFFER LAYER

p+ INJECTING LAYER
p+ INJECTING LAYER
DRAIN DRAIN
A. PASSIVE B. ACTIVE
INSULATED GATE BIPOLAR TRAN- PULSE WIDTH MODULATION

SISTOR (IGBT) OPERATION The term PULSE WIDTH MODULATION (PWM) is
An IGBT is a type of transistor. IGBTs are semiconduc- used to describe how much time is devoted to conduc-
tors well suited for high frequency switching and high tion. Changing the pulse width is known as MODULA-
current applications. Drawing A shows an IGBT in a TION. Pulse Width Modulation is the varying of the
pulse width over the allowed range of a cycle to affect
passive mode. There is no gate signal, (zero volts rel-

ative to the source) and therefore, no current flow. The the output of the machine.
drain terminal of the IGBT may be connected to a volt-
age 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 con-
nected to the drain terminal will allow the IGBT to con-
duct and supply current to circuit components coupled
to the source. Current will flow through the conducting
IGBT to downstream components as long as the posi-
tive gate signal is present. This is similar to turning ON
a light switch.

POWER WAVE® S500

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-10

NOTES
POWER WAVE® S500

E-10
Return to Master TOC 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 F-2
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 Step 3. RECOMMENDED
help you locate and repair possible machine COURSE OF ACTION
malfunctions. Simply follow the three-step The last column labeled “Recommended
procedure listed below. Course of Action” lists the most likely com-
ponents that may have failed in your
Step 1. LOCATE PROBLEM (SYMPTOM). machine. It also specifies the appropriate
Look under the column labeled “PROBLEM test procedure to verify that the subject com-
(SYMPTOMS)”. This column describes pos- ponent is either good or bad. If there are a
sible symptoms that the machine may exhib- number of possible components, check the
it. Find the listing that best describes the components in the order listed to eliminate
symptom that the machine is exhibiting. one possibility at a time until you locate the
Symptoms are grouped into the following cause of your problem.
categories: output problems, ethernet prob-
lems and welding problems. All of the referenced test procedures
referred to in the Troubleshooting Guide are
Step 2. PERFORM EXTERNAL TESTS. described in detail at the end of this chapter.
The second column labeled “POSSIBLE Refer to the Troubleshooting and Repair
AREAS OF MISADJUSTMENT(S)” lists the Table of Contents to locate each specific
obvious external possibilities that may con- Test Procedure. All of the specified test
tribute to the machine symptom. Perform points, components, terminal strips, etc. can
these tests/checks in the order listed. In be found on the referenced electrical wiring
general, these tests can be conducted with- diagrams and schematics. Refer to the
out removing the case wrap-around cover. Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
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

PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag

WARNING and place it directly into the equipment. Donʼt set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board canʼt be
installed immediately, put it back in the static-shield-
• Have an electrician install and ing bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do donʼt remove them until installation is complete.
not touch electrically hot parts.
- 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 prop-
CAUTION er failure analysis.
Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure
board failures. These problems can sometimes be symptom has been corrected by the
traced to poor electrical connections. To avoid prob- replacement PC board.

lems 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 NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly 5. Remove the replacement PC board and
connected. substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
a. If the original problem does not reappear by
board using standard practices to avoid static
substituting the original board, then the PC
electrical damage and electrical shock. Read
board was not the problem. Continue to look
the warning inside the static resistant bag and
for bad connections in the control wiring
perform the following procedures:
harness, junction blocks and terminal strips.
PC board can be damaged by static electricity. b. If the original problem is recreated by the
- Remove your bodyʼs static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
ATTENTION to a grounded part of the submitted.
Static-Sensitive equipment frame.
NOTE: Following this procedure and writing on the
Devices - If you donʼt have a wrist strap, warranty report, “INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded,
BOARDS TO VERIFY PROBLEM,” will help avoid
Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims.
Workstations touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
POWER WAVE® S500

Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized 1. Contact the Lincoln Electric
is evident when the Power Wave® Lincoln Electric Service Facility Service Department at 1-888-
S500 case is removed. 935-3877.
The input fuses repeatedly fail or the 1. Make certain the fuses or break- 1. Perform the Input Board Test.
input circuit breakers keep tripping. ers are properly sized.
2. Perform the Power Conversion
2. The welding procedure may be Assembly Test.
drawing too much input current
3. Perform the PFC Control Board
or the duty cycle may be too
Test.
high. Reduce the welding cur-
rent and/or reduce the duty
cycle.
3. Check for error codes. See
Status LED Troubleshooting in
this section.
The machine will not power up. No 1. Make sure the proper input volt- 1. Check the input line switch for
lights or displays. The machine age is being applied to the proper operation. Also check the
appears to be off. machine (check fuses or break- associated leads for loose or
ers). faulty connections. See the
Wiring Diagram.
2. Make sure the input supply dis-
connect has been turned ON. 2. Check to make sure that 40VDC
is being applied to the Optional
3. Make certain the input power line
User Interface Board at lead
switch is in the ON position.
52D(+) to lead 51D(-). See the
4. Check for error codes. See Wiring Diagram.

3. Perform the 40 Volt DC Bus
this section.
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



OUTPUT PROBLEMS
The Power Wave S500 does not
®
1. If the symptom is accompanied 1. Perform the Input Board Test.
have welding output. by an error code see the Status
2. Perform the Power
LED Troubleshooting section.
Conversion Assembly Test.
2. There may be an external “short”
3. Perform the Digital Control
in the external output circuitry.
Board Test.
Remove all loads from the output
terminals and restart the 4. Perform the 40 Volt DC Bus
machine. Board Test.
3. If the thermal LED is lit the unit 5. Perform the Optional User
may be overheated. Adjust the Interface Kit Test.
welding load and /or duty cycle to
6. Perform the Multi-Phase

coincide with the output limits of
Output Choke Test.
the Power Wave® S500. Also see
the symptom “The Thermal LED
is ON” in this section.
The Thermal LED is ON. The 1. The welding application may be 1. Check the thermostats and
machine regularly overheats. There exceeding the recommended associated wiring for loose or
is no welding output. duty cycle and/or current limits of faulty connections. See the
the machine. Wiring Diagram.
2. Dirt and dust may have clogged 2. Check the DC voltage being
the cooling channels inside the applied to the fans. There
machine. See the Maintenance should be 48VDC at lead 351 (-)
Section of this manual. to lead 353 (+). See the Wiring
Diagram.
3. The air intake and exhaust lou-
vers may be blocked due to inad-
equate clearance around the

machine.
4. Make sure the fans are function-
ing 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
Call 1-888-935-3877.
POWER WAVE® S500



OUTPUT PROBLEMS
The “Real Time Clock” no longer 1. The Digital Control Board Battery 1. The Digital Control Board
functions. may be faulty. Battery may be faulty. Replace
if necessary (Type BS2032).
2. The Digital Control Board may
be faulty.
Board Test.
The Power Wave® S500 will not 1. The input voltage may be too 1. Perform the Current Transducer
produce full output. low. Check for error codes. See Test.

2. Perform the Current and

this section.
Voltage Calibration Procedure.
2. Make certain the three-phase
input voltage is correct for the
Board Test.
machine.
4. Perform the Power Conversion
Assembly Test.
5. Perform the Multi-Phase Output
Choke Test.
CAUTION
Call 1-888-935-3877.
POWER WAVE® S500



WELDING PROBLEMS
General degradation of the welding 1. Check for proper wire feeding. 1. Perform the Current and
performance Make certain that the actual Voltage Calibration Procedure.
speed is the same as the preset.
2. Verify that the correct wire drive
and gear ratio have been select-
ed.
3. Check the welding cables for
loose or faulty connections.
4. Check for adequate gas shield-
ing.
5. Make sure the welding process is

correct for the wire feed and volt-
age settings.
The wire burns back to the tip at the 1. Reduce the burnback time. N/A.
end of the weld.
2. Reduce the workpoint.
During a weld the machine shuts 1. The secondary current limit has 1. A non-recoverable internal fault
down. been exceeded and the machine will interrupt the welding output.
shuts down to protect itself. This condition will also result in
Adjust the procedure to reduce a status light blinking. Check for
the load and lower the output cur- error codes. See Status LED
rent draw. Troubleshooting in this sec-
tion.
CAUTION
Call 1-888-935-3877.
POWER WAVE® S500



WELDING PROBLEMS
The arc is excessively long and 1. In the wirefeeder make sure the 1. Perform the Current and
erratic. correct wire drive and gear ratio Voltage Calibration Procedure.
have been selected for the weld-
ing process being used.
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 N/A.
on the wirefeeder is adjusted cor-
rectly. Also the welding wire

should travel freely through wire
feeding path. Check the welding
tip for blockage.
2. Make sure the shielding gas flow
is correct.
The end of the weld is not accept- 1. Make sure all of the settings for N/A.
able. Burnback and Crater states are
set correctly for the welding
process being used. Verify that
the Burnback has a value other
than 0.
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 1. Check the ArcLink cable con- 1. Perform the 40 Volt DC Bus
power up. necting the Power Wave® S500 Board Test.
to the ArcLink wirefeeder.
CAUTION
Call 1-888-935-3877.
POWER WAVE® S500



ETHERNET PROBLEMS
The system will not connect. 1. Make sure that the correct patch 1. Use Weld Manager (included
cable or cross over cable is being on the Power Wave Utilities and
used. available at www.power-
wavesoftware.com) to verify
2. Make sure the software is not
the correct IP address informa-
blocking the connection. See the
tion has been entered.
on line Diagnostic Utility.
2. Verify that no duplicate IP
3. Verify that the cables are fully
addresses exist on the network
inserted into the bulk head con-
nector.
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 connect-
ed to another network device.
The Ethernet connection drops out 1. Make sure all of the connections 1. Make certain that the network
while welding. are tight and secure. cable is not located next to any
heavy current carrying conduc-
tors. This would include input
power cables and welding out-
put cables.
CAUTION
Call 1-888-935-3877.
POWER WAVE® S500


INPUT CONTROL BOARD

Error Code # Indication Type
331 Instantaneous Instantaneous input current limit has been exceeded. Typically indi- Persistent
Input Current Limit cates short term power overload.
334 Startup Current Input current limit was exceeded during machine power-up. Persistent
Check Failure
335 Startup Voltage Input voltage was too high or too low during machine power-up. Verify Temporary
Check Failure that the input voltage is between 200V and 650V.
336 Thermal Fault Thermostat on primary module is tripped. Typically caused by a fan Temporary
malfunction or blocked air vent. Check for proper air flow around and
through the system. Verify that the thermal circuit has not been dam-
aged or disconnected.
337 Precharge Timeout The DC bus voltage was not charged to a certain level at end of Persistent
precharge.
338 Input Power Limit The input power drawn by the machine exceeded a safe level. Persistent
339 Current Imbalance The current through the power modules is out of balance. Could indi- Temporary
Fault cate a faulty connection to a power module or a malfunctioning power
module.
341 Input Voltage The input voltage momentarily dropped out. Check connections and Temporary
Dropout verify quality of input power.
346 Transformer Transformer current too high. Typically indicates short-term power Persistent
Primary Overcurrent overload.
347 Average Input Average input current limit has been exceeded. Typically indicates Persistent
Current Limit short term power overload.
349 Bus Undervoltage The DC bus voltage dropped below the allowable limit. Temporary
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.
CAUTION
Call 1-888-935-3877.
POWER WAVE® S500


MAIN CONTROL BOARD (“STATUS” LIGHT)

Error Code # Indication Type
36 Thermal Error Indicates over temperature. Usually accompanied by thermal LED. Temporary
Check fan operation. Be sure process does not exceed duty cycle limit
of the machine. Check for proper air flow around and through the sys-
tem. Verify that the thermal circuit has not been damaged or disconnect-
ed.
45 Output Voltage High Welding voltage exceeded allowable limit. Check sense lead connec- Persistent
tion, voltage feedback circuits and voltage calibration. Verify that the
machine is programmed with the latest firmware.
52 DSP ADC Load High The control board DSP is experiencing a CPU overload. Verify that the Persistent
machine is programmed with the latest firmware. If problem persists,
perform the Control Board Removal And Replacement Procedure.
55 Communication with Communication with the control board DSP failed. Verify that the Persistent
DSP Failed machine is programmed with the latest firmware. If problem persists,
54 Secondary (Output) The long-term average secondary (welding) current limit has been Temporary
Overcurrent Error exceeded. NOTE: The long-term average secondary current limit is
325A (1 phase) or 575A (3 phase).
56 Chopper Indicates communication link between main control board and chopper Temporary
Communication Error 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 prob-
lem persists, perform the Chopper Board Removal And Replacement
Procedure.
58 Primary Fault The PFC control board is not ready. Check that board for information on Temporary
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.
71 Secondary (Output) The long-term secondary (welding) power limit has been exceeded. Temporary
Overpower Error 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 Temporary
machine is programmed with the latest firmware. If problem persists,
CAUTION
Call 1-888-935-3877.
POWER WAVE® S500

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-12

NOTES
POWER WAVE® S500

F-12
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.
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting 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
POWER WAVE® S500


CAPACITOR DISCHARGE PROCEDURE (continued)

FIGURE F.1 – CASE COVER REMOVAL
TOP CORNER
END CAPS
(4)
LEFT SIDE
MOUNTING SCREWS
(6)
REMOVAL PROCEDURE
3. Using a 5/16” nutdriver, remove the six remain-
WARNING ing screws and washers from the left side to
gain access to the left side internal compo-
ELECTRIC SHOCK can kill. nents. See Figure F.1.
• Do not touch electrically live 4. Locate the DC Link Capacitor and carefully
parts or electrodes with your check the voltage across it. The test probes
skin or wet clothing. should be carefully placed at the connection
points B4 (+) and B5 (-). See Figure F.2. If any
• Insulate yourself from the work and ground. voltage is present discharge the capacitor using
• Always wear dry insulating gloves. 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
1. Remove input power to the Power Wave® S500 resistor terminals on the capacitor terminals for
machine. 10 seconds.
2. Using a 5/16” nutdriver, remove the four top cor-
ner end caps as shown in Figure F.1. Keep the
screws and flat washers for reassembly.
POWER WAVE® S500



FIGURE F.2 – CAPACITOR DISCHARGE PROCEDURE
B2
J32 J33 B28 L3
R74
9
R75
C35
R70
R66
R7
LED4
R71
LED3
B13
LED5
C10
FTP3
LEAD B5
R53
C12
DZ25
B2
B1
B3
DZ23
R36
R29
DZ22
C9
D14
R30
D15 R34
C19 R35
R31
R50
R51
R49
DZ26 DZ24 R1
R54 R27
B11
11 C11 R3 B16
T4 R2
DZ17
DZ3
R60
T3 R61
D4
DZ11
DZ1
R67
R58
R45
R8
D5
D2
C38
DZ4
R55
DZ9
R59
R47
DZ12
C15
R16
R15
DZ10
D3
R48
R18
R17
OCI1
C16
D1
B12
R52 B5
DZ2
R46
C14
R14
R13
X1
LEAD B4
J37
R12
C13
R11
C21
C18 C40
D12
D13
B8
C25
T5
C17
L2 C33
B56
C23
B20
L4
B7
B58
R81
B6 X2
D11
R80
R79
B57
D10
B1
B18
7
R78
B23
C24
C20
S500 POWER
LED2
FTP1
LEAD B58
G6846-1
R28
DZ21
C36 C2 DZ19
R39
R6
R37
C22
DZ18
D16
R9
C1
R68
R32
R38
R4
R63
B10
HEAT SINK B4
D7
C4
R5
TERMINAL
R10
R69
DZ20
D17
R33
J36
DZ15
R20
DZ5
R40
C39
C3
C7 R21
R22
C8
R44
R62
B15
B9 D6
R19
T2
R43
DZ6
DZ16
R65 DZ14
R72
R73
LED1
B55
D9
B44
R42
R25
D8
R64
DZ13 T1 DZ8 R26

C37
DZ7
C6
T6
C5
R24
R41 R23
L1
R77
R76
J35 J34 C34

5. Recheck the voltage across the B4 and B5 ter-

minals. The voltage should be zero. If any volt-
age 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 connec-
tion 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 remain-
ing 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


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.
and washers securing the left side case cover.
4. Using a 5/16” nutdriver, screws and flat wash-
ers previously removed, attach the four top cor-
ner end caps.

POWER WAVE® S500

PFC CONTROL BOARD TEST

WARNING
manual.
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
POWER WAVE® S500

PFC CONTROL BOARD TEST (continued)

FIGURE F.3 – PFC CONTROL BOARD LOCATION
PFC CONTROL
BOARD
PFC BOARD
MOUNTING PANEL
FRONT PANEL
ASSEMBLY
PROCEDURE
4. Carefully apply the correct input power to the
WARNING Power Wave® S500 machine.
5. Check for the correct operation of the LED
ELECTRIC SHOCK can kill. lights on the PFC Control Board. See Figure
• Do not touch electrically live F.4 and Tables F.1 and F.2.
parts or electrodes with your 6. Remove the input power to the Power Wave®
skin or wet clothing. S500 machine and perform the Capacitor
• Insulate yourself from the work and ground. Discharge Procedure.
• Always wear dry insulating gloves. 7. If further testing is required, perform the PFC
Control Board Removal Procedure.
-------------------------------------------------------------------
8. Perform the resistance and diode checks per
1. Remove the input power to the Power Wave ® Table F.3, Table F.4 and Figure F.4.
S500 machine. 9. When testing is complete, perform the PFC

2. Perform the Case Cover Removal and Control Board Replacement Procedure.
Capacitor Discharge Procedure. 10. Perform the Case Cover Replacement
3. Locate the PFC Control Board located on the Procedure.
inside of the front panel. See Figure F.3. 11. Perform Retest After Repair Procedure.
POWER WAVE® S500


FIGURE F.4 – PFC CONTROL BOARD LED AND TEST POINTS
PIN 1 J23A PIN 16 LED2 J23B
FTP25
C4 C6
FTP27
J23A FTP9 FTP7 J23B
R7
R8
R3
R4
D9 D11
D17
D8
D22
D21
D5 D6 D7 C5 D18 D19 D20
D2
D1
C7 Q10
T1
FTP19
FTP8 X7
FTP28
PIN 1
X1
C8
C9
X2 X3 D10 D12 X5 X6 Q1
C2
C3
D23
D24
D3
D4
Q9
Q2
FTP16
C20
D14
D16
C12
C1 X4 C10
DZ1
DZ2
DZ3
DZ4
DZ5
DZ6
DZ7
DZ8
C11
C24
C25
C23
C21
D13
D15
X8 X12
D25
L1
OCI1 OCI2 OCI3 OCI4

D28 D29
J24
D43
D44
J24
X18 X19 X17 X16
FTP23
R257
D26 D27
R65
C13 C14
DZ10
FTP20
C19
Q4
FTP21
D45
D46
D47
D48
C35
Y2
D30
D31
D41
D42
D39
D40
X31 FTP5
C15
LED5
X13 X14
C17
LED2
1
FTP35
FTP37
FTP36
FTP33
FTP34
LED5
C27
C26
J2
FTP14
FTP4
Y1
FTP26
FTP13
C22
C16
FTP31 FTP32
FTP15 1 J1 X20
X22
1
D52
D53
D54
D55
DZ9
X21
Q3 D49 FTP6
X24
J25
FTP38
FTP10
J25
C74
R56
R57
FTP24
X10
LED1
X26 OCI5
FTP12
FTP18
FTP22
C39
R92
DZ11
R86
FTP11
J22 X25
J22
C66
R91
FTP2
DZ12
DZ17
FTP30
DZ18
R110
X27
LED3
FTP1
D36 D33 D35 D38 D34 D37
R84
D51
FTP17
D64
DZ19 D56
D58
X9 C30
D50
C29 Q8
D57 C31
J21
DZ20
FTP29 FTP40
J21
D62
D59
D68
D65
D63 X29 X30 Q7

4
T2
J26
D61
J26
D60
J20
DZ22
J20
C32
R2
D67 D66 6
C33
Q6
C34
G6860-1
R210
R209
R212
LED4
D69
FTP3
LED3 LED4 LED1

TABLE F.1 – PFC CONTROL BOARD LED DESCRIPTION AND FUNCTIONS
LED NUMBER COLOR FUNCTION

1 GREEN Status is OK
1 RED / FLASHING Error Code (Blinking)
2 RED Fault on “B” side of bridge
3 GREEN -15VDC present
4 GREEN +15VDC present
5 RED Fault on “A” side of bridge
TABLE F.2 – PFC CONTROL BOARD ERROR CODES
ERROR CODE NUMBER EXPLANATION
331 Peak input current limit
334 Start up current check failure
335 Start up voltage check failure
336 Thermal fault
337 Precharge failure

338 Input power limit
341 Input voltage drop-out
346 Transformer primary overcurrent
347 Average input current limit
349 Bus undervoltage
POWER WAVE® S500


TABLE F.3 – PFC CONTROL BOARD RESISTANCE CHECKS
DESCRIPTION METER TEST POINTS EXPECTED READINGS CONDITIONS

AND POLARITY
INPUT POWER CIRCUIT PLUG J26 PIN 4 (+) VERY HIGH RESIS- INPUT POWER
TO TANCE. GREATER THAN REMOVED. PLUG J26
PLUG J26 PIN 6 (–) 20,000 OHMS REMOVED FROM PFC
BOARD
INPUT LINE SENSING PLUG J25 PIN 1 (+) VERY HIGH RESIS- IF LOWER REPLACE
TO TANCE. GREATER THAN THE PFC BOARD
PLUG J26 PIN 6 (–) 500,000 OHMS
TABLE F.4 – PFC CONTROL BOARD DIODE CHECKS

DESCRIPTION POSITIVE METER LEAD NEGATIVE METER LEAD EXPECTED READINGS

+/– 10%*
MAIN BUCK DRIVE “A” PLUG J23A PIN 8 PLUG J23A PIN 16 0.130VDC
AUX. BUCK DRIVE “A” PLUG J23A PIN 6 PLUG J23A PIN 14 0.130VDC
MAIN BOOST DRIVE “A” PLUG J23A PIN 12 PLUG J25 PIN 12 0.130VDC
MAIN BOOST DRIVE “A” PLUG J23A PIN 4 PLUG J23A PIN 12 0.130VDC
AUX. BOOST DRIVE “A” PLUG J23A PIN 11 PLUG J25 PIN 12 0.130VDC
AUX. BOOST DRIVE “A” PLUG J23A PIN 3 PLUG J23A PIN 11 0.130VDC
FULL BRIDGE “A” PLUG J24 PIN 7 PLUG J25 PIN 12 0.130VDC
FULL BRIDGE “A” PLUG J23A PIN 3 PLUG J24 PIN 7 0.130VDC
FULL BRIDGE “A” PLUG J24 PIN 3 PLUG J25 PIN 12 0.130VDC
FULL BRIDGE “A” PLUG J23A PIN 3 PLUG J24 PIN 3 0.130VDC
MAIN BUCK DRIVE “B” PLUG J23B PIN 1 PLUG J23B PIN 9 0.130VDC
AUX. BUCK DRIVE “B” PLUG J23B PIN 3 PLUG J23B PIN 11 0.130VDC
MAIN BOOST DRIVE “B” PLUG J23B PIN 13 PLUG J25 PIN 12 0.130VDC
MAIN BOOST DRIVE “B” PLUG J23B PIN 5 PLUG J23B PIN 13 0.130VDC
AUX. BOOST DRIVE “B” PLUG J23B PIN 14 PLUG J25 PIN 12 0.130VDC
AUX. BOOST DRIVE “B” PLUG J23B PIN 6 PLUG J23B PIN 14 0.130VDC
FULL BRIDGE “B” PLUG J24 PIN 6 PLUG J25 PIN 12 0.130VDC
FULL BRIDGE “B” PLUG J23B PIN 6 PLUG J24 PIN 16 0.130VDC
FULL BRIDGE “B” PLUG J24 PIN 2 PLUG J25 PIN 12 0.130VDC
FULL BRIDGE “B” PLUG J23B PIN 6 PLUG J24 PIN 2 0.130VDC
NOTE: *An open or short indicates a faulty PFC Control Board.

POWER WAVE® S500

DIGITAL CONTROL BOARD TEST

WARNING
manual.
TEST DESCRIPTION
This test will help determine if the Digital Control Board is receiving the correct input volt-
age 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
POWER WAVE® S500

DIGITAL CONTROL BOARD TEST (continued)

FIGURE F.5 – DIGITAL CONTROL BOARD LOCATION

DIGITAL CONTROL
BOARD
PROCEDURE
WARNING 5. Carefully apply the correct input voltage to the

Power Wave® S500 machine.
ELECTRIC SHOCK can kill. 6. Check for the correct operation of the LED
lights on the Digital Control Board. See Figure
• Do not touch electrically live F.6 and Table F.5.
parts or electrodes with your
skin or wet clothing. 7. Perform the voltage tests per Table F.6. See
Figure F.6.
• Insulate yourself from the work and ground.
8. Remove the input power to the Power Wave®
• Always wear dry insulating gloves. S500 machine and perform the resistance
------------------------------------------------------------------- checks per Table F.7.
1. Remove the input power to the Power Wave® 9. If the correct input voltage is being applied to
S500 machine. the Digital Control Board and the correct output
2. Perform the Case Cover Removal and voltages are not being generated, the Digital
Capacitor Discharge Procedure. Control Board may be faulty.
3. Locate the Digital Control Board located on the 10. If faulty, perform the Digital Control Board
underside of the top case panel. See Figure Removal And Replacement Procedure.
F.5. 11. Perform the Case Cover Replacement
4. Locate Plugs J4, J5, J8, J9, J5 and J12 located Procedure.
on the Digital Control Board. See Figure F.6. 12. Perform the Retest After Repair Procedure.
See Wiring Diagram.
POWER WAVE® S500


FIGURE F.6 – DIGITAL CONTROL BOARD LED AND TEST POINT LOCATIONS
J5 J6 LED 1 J7 LED 2 J8 J9
DZ1
DZ2
D1 D3
6 2
D47
D46
D45
D44
Q3 Q6
D7
D9
J5 J6 J7 J8 J9
D19
DZ7
DZ6
11 6 7
D22
D4 D6
DZ8
D8 X100
LED1
LED2
X26
D10
D11
Q1 D17
J3
D2 D5 X11
DZ3
DZ4
X8
X94 X96 X95 X97
D16
DZ5
X5 X9 X10
L2
X79
X4 X99 X24
C6
L1
Q24 X93 X98 C8
OCI2
X15
X13
X22
X40
Q11 Q14
Q25 X75 Q31 X38 X21
X18 X19
X39
12 X20
FTP8
FTP6
O O
N N
X14
S3 S1
OCI1
FTP7
Q10 X41 X25 X36 X85 X12
J12
J12
L6
LED 3, 4, 5, 6
LED3
LED6
3
C110
X33 Q16 X34
X83 X82 X29 X28
LED4
LED5
L8
C325
FTP4
FTP5
L14
Y1 X92
X32
X81
L5
L13
L4
FTP2
R510 X35
BT1
Y2 FTP1
R6
X50
X47
D54
R12
X46 R21 X51
X48
FTP3
D55
X52
LED 8 R15
L7
X49
LED9 C9 C10 CT1
X78
C255
LED8
T1
Y3 X63
X62 Q20 C11 C12
J15
X53 R24
X61
L9
LED7
D30
X77
Q18
X65
X1
L10
OCI7 OCI8 L11 L12
LED 7
X58
DIGITAL CONTROL
T2
G6682-1
DZ31 DZ32
OCI10 OCI9 C14
X54
Q19
X60
O X59 C13
Q21
N D38 D39 D40 D41

S2 OCI5 OCI6
D37
C17
C15 X64
D35 X68 Q22 Q23
C19 C22
LED10
X67
D42
DZ24
DZ23
D43
C20
8 C18
X70
J13 J2 J4 X72 X73 X74
J11
C287
1
C252
X57 C21
X69
X71
C292
OCI12
J11 LED 10 J4 LED 9
TABLE F.5 – DIGITAL CONTROL BOARD LED DESCRIPTION AND FUNCTIONS

LED NUMBER COLOR FUNCTION

1 GREEN STATUS IS OK
2 RED ERROR CODE (BLINKING)
3 GREEN WELDING OUTPUT ENABLED
4 GREEN SINGLE PHASE INPUT
5 GREEN ELECTRODE SENSE
6 GREEN WORK SENSE
7 GREEN ETHERNET LINK / ACTIVITY STATUS
8 GREEN ETHERNET SPEED STATUS
9 GREEN INPUT SUPPLY STATUS (30VDC TO 50VDC)
10 GREEN DEVICENET EXTERNAL 24VDC PRESENT
POWER WAVE® S500


TABLE F.6 – DIGITAL CONTROL BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS
DESCRIPTION TEST POINTS LEAD NUMBERS EXPECTED CONDITIONS

READING
INPUT SUPPLY FROM J4 PIN 2 LEAD 356 (–) 40VDC INPUT POWER
PFC BOARD TO TO APPLIED TO
J4 PIN 1 LEAD 358 (+) MACHINE
POWER FROM DIGITAL J12 PIN 12 LEAD 348 (–) 5VDC INPUT POWER
CONTROL BOARD TO TO TO APPLIED TO
CHOPPER BOARD J12 PIN 3 LEAD 344 (+) MACHINE
FAN CONTROL SIGNAL J7 PIN 16 LEAD 350 (–) 10VDC INPUT POWER
TO TO APPLIED AND FAN
J7 PIN 6 LEAD 355 (+) RUNNING
POWER SUPPLY TO J8 PIN 6 LEAD 214 (–) +15VDC INPUT POWER

CURRENT TRANSDUCER TO TO APPLIED TO
POWER SUPPLY TO J8 PIN 6 LEAD 214 (–) -15VDC INPUT POWER
CURRENT TRANSDUCER TO TO APPLIED TO
SUPPLY TO OPTIONAL J8 PIN 7 LEAD 417 (–) 15VDC INPUT POWER
INVERTER BOARD TO TO APPLIED TO
TABLE F.7 – DIGITAL CONTROL BOARD RESISTANCE CHECKS AND EXPECTED READINGS
DESCRIPTION TEST POINTS LEAD NUMBERS EXPECTED CONDITIONS

READING
CONNECTIONS TO J9 PIN 3 LEAD 202 ZERO OHMS NO INPUT POWER
OUTPUT TERMINALS TO TO APPLIED TO

NEGATIVE NEGATIVE MACHINE
OUTPUT OUTPUT
TERMINAL TERMINAL
J9 PIN 1 LEAD 206

TO TO
ZERO OHMS
POSITIVE POSITIVE
OUTPUT OUTPUT
TERMINAL TERMINAL
CONNECTIONS TO J5 PIN 2 LEAD 410 ZERO OHMS NO INPUT POWER
NORMALLY CLOSED TO TO APPLIED TO
THERMOSTATS J5 PIN 3 LEAD 409 MACHINE
POWER WAVE® S500

OPTIONAL USER INTERFACE KIT TEST

WARNING
manual.
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
POWER WAVE® S500

OPTIONAL USER INTERFACE KIT TEST (continued)

FIGURE F.7 – USER INTERFACE AND REMOTE INTERFACE BOARD LOCATIONS
OPTIONAL REMOTE
INTERFACE BOARD
OPTIONAL USER
INTERFACE BOARD
PROCEDURE
5. Locate Plugs J114, J111, J112 and J115 on the
WARNING
Remote Interface Board. See Figure F.8. Also

locate Plug J115 on the User Interface Board.
ELECTRIC SHOCK can kill. See Figure F.9. See Wiring Diagram.
• Do not touch electrically live 6. Carefully check for the expected voltages per
parts or electrodes with your Table F.8 and Table F.9.
skin or wet clothing.
7. If the correct input voltages are being applied to
• Insulate yourself from the work and ground. the Remote Interface Board and the correct out-
• Always wear dry insulating gloves. puts are not being generated, the Remote
Interface Board may be faulty.
-------------------------------------------------------------------
8. If faulty, replace the Remote Interface Board.
S500 machine. 9. If the correct voltages are present remove the
input power and perform the resistance tests
2. Perform the Case Cover Removal and
per Table F.10. Also see the Wiring Diagram.
Capacitor Discharge Procedure.
10. Perform the Case Cover Replacement
3. Locate the Optional User Interface Kit Boards.

Procedure.
The User Interface Board is located on the front
panel of the machine. See Figure F.7. The 11. Perform the Retest After Repair Procedure.
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

J115
R49 R51
R50 R48
J116 J115
4

3
4
R52
J114
Q9
R56 R44 R47 OCI2
Q10
6
J114
R57 R2 R43
D6 R40 C7 R20 C9
C10 R27
R1 R23
R9 R55
1
D1 R10
R41 R54
R7
X1
D4 R28
2
R29
S1 R42 R53 R11
C4
3
R45 R25
6 7 8
3
J111
D5 R26
4
R12 DZ4
C2 R5
J111
R58 R13
R16 C5
R6 R38
R8 C1 R24 R33
R15 R39 R35
DZ1 R37
Q6
R22
R14
Q2
D3
R3 C8
R18 DZ6
R19
R21
5 6
DZ5
POWER WAVE® S500

J112
Q1 R30
C3
R17
J112
D2
DZ2
Q7
C6
OCI1
Q5
Q4
R4
12 PIN
R36
Q3
R34
J113
DZ3
R31
INTERFACE
R32
G6948-1
4 2
3 1
FIGURE F.9 – USER INTERFACE BOARD TEST POINTS
TROUBLESHOOTING AND REPAIR
FIGURE F.8 – REMOTE INTERFACE BOARD TEST POINTS

J115
F-27

TABLE F.8 – VOLTAGE CHECKS ON REMOTE INTERFACE BOARD
DESCRIPTION TEST POINT TEST POINT EXPECTED CONDITIONS

METER PROBE (+) METER PROBE (–) READING
40VDC BUS PLUG J114 PIN 6 PLUG J114 PIN 4 40VDC CORRECT INPUT
SUPPLY FROM DC (LEAD 52C) (LEAD 51C) POWER APPLIED
BUSS BOARD TO MACHINE
40VDC FROM PLUG J111 PIN 8 PLUG J111 PIN 7 40VDC CORRECT INPUT
REMOTE (LEAD 52F) (LEAD 51F) POWER APPLIED
INTERFACE BOARD TO MACHINE
TO S1 REMOTE
RECEPTACLE
40VDC FROM PLUG J115 PIN 4 PLUG J115 PIN 3 40VDC CORRECT INPUT
REMOTE (LEAD 52D) (LEAD 51D) POWER APPLIED

INTERFACE BOARD TO MACHINE
TO THE USER
INTERFACE BOARD
15VDC TRIGGER PLUG J112 PIN 6 PLUG J112 PIN 5 12VDC CORRECT INPUT
SUPPLY FROM THE (LEAD 373) (LEAD 370) POWER APPLIED
DIGITAL CONTROL TO MACHINE
BOARD
15VDC TRIGGER PLUG J111 PIN 6 PLUG J111 PIN 3 15VDC TRIGGER NOT
SUPPLY FROM THE (LEAD 2) (LEAD 4) ACTIVATED (OPEN)
REMOTE BOARD
15VDC TRIGGER PLUG J111 PIN 6 PLUG J111 PIN 3 0VDC TRIGGER
SUPPLY FROM (LEAD 2) (LEAD 4) ACTIVATED
REMOTE BOARD (CLOSED)
15VDC TRIGGER PLUG J112 PIN 4 PLUG J112 PIN 5 0VDC TRIGGER NOT
SUPPLY FROM (LEAD 372) (LEAD 370) ACTIVATED (OPEN)

REMOTE BOARD
15VDC TRIGGER PLUG J112 PIN 4 PLUG J112 PIN 5 15VDC TRIGGER
SUPPLY FROM (LEAD 372) (LEAD 370) ACTIVATED
REMOTE BOARD (CLOSED)
TABLE F.9 – VOLTAGE CHECKS ON USER INTERFACE BOARD

40VDC SUPPLY PLUG J115 PIN 4 PLUG J115 PIN 3 40VDC CORRECT INPUT
FROM REMOTE (LEAD 52D) (LEAD 51D) POWER APPLIED
BOARD TO MACHINE
POWER WAVE® S500


TABLE F.10 – RESISTANCE CHECKS

METER PROBE METER PROBE READING
CONTINUITY PLUG J111 PIN 5 S1 RECEPTACLE ZERO OHMS POWER TO
CHECK FROM (LEAD 75) PIN C (LEAD 75) MACHINE
PLUG J111 TO REMOVED
12 PIN S1
RECEPTACLE
CHECK FROM (LEAD 76) PIN D (LEAD 76) MACHINE
12 PIN S1
RECEPTACLE
CHECK FROM (LEAD 77) PIN E (LEAD 77) MACHINE
12 PIN S1
RECEPTACLE
CONTINUITY PLUG J115 PIN 1 PLUG J115 PIN 1 ZERO OHMS POWER TO
CHECK FROM (LEAD 53D) (LEAD 53D) MACHINE
PLUG J115 ON REMOVED
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD

REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
REMOTE BOARD
TO PLUG J115 ON
USER INTERFACE
BOARD
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-30
POWER CONVERSION ASSEMBLY TEST

WARNING
manual.
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
POWER WAVE® S500

POWER CONVERSION ASSEMBLY TEST (continued)

FIGURE F.10 – POWER CONVERSION ASSEMBLY LOCATION
POWER CONVERSION
ASSEMBLY
PROCEDURE
WARNING 5. Locate the five Green LEDs on the Power
Conversion Assembly. See Figure F.12.
ELECTRIC SHOCK can kill. 6. Carefully apply the correct three phase input
power to the Power Wave® S500 machine.
• Do not touch electrically live
parts or electrodes with your 7. Check the Buck/Boost Circuits using the LED
skin or wet clothing. Table F.12. See Figure F.12.
• Insulate yourself from the work and ground. 8. Perform the voltage checks. See Table F.13
and Figure F.12.
------------------------------------------------------------------- S500 machine.
10. If any of the above test results are not correct
S500 machine.
the Power Conversion Assembly may be faulty.
11. If faulty, perform the Power Conversion
Board Assembly Removal and Replacement
3. Locate the Power Conversion Assembly locat- Procedure.
ed on the left side of the machine. See Figure

F.10.
Procedure.
4. Perform the Power Conversion diode tests per
13. Perform the Retest After Repair Procedure.
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


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 recon-
nect the three leads to terminal B56.
TEST DESCRIPTION POSITIVE METER LEAD NEGATIVE METER LEAD MEASURED LEAD
SIDE A BUCK IGBT B13 B29 0.395 (+/– 10%)
SIDE A BOOST IGBT B28 B8 0.395 (+/– 10%)

SIDE A HIGH B16 B58 0.395 (+/– 10%)
SPEED H-BRIDGE B5 B58 0.395 (+/– 10%)
B28 B16 0.395 (+/– 10%)
B28 B5 0.395 (+/– 10%)
SIDE B BUCK IGBT B7 B17 0.395 (+/– 10%)
SIDE B BOOST IGBT B18 B6 0.395 (+/– 10%)
SIDE B HIGH B4 B58 0.395 (+/– 10%)
SPEED H-BRIDGE B15 B58 0.395 (+/– 10%)
B18 B4 0.395 (+/– 10%)
B18 B15 0.395 (+/– 10%)
OUTPUT RECTIFIER B11 B57 0.335 (+/– 10%)
B12 B57 0.335 (+/– 10%)

B9 B57 0.335 (+/– 10%)
B10 B57 0.335 (+/– 10%)
POWER WAVE® S500


FIGURE F.11 – POWER CONVERSION ASSEMBLY DIODE TEST POINTS
J32 J33
B28 L3 B29
R74
R75
C35
R70
R66
R7
LED4
R71
LED3
LED5 XXXX C10

FTP3 B13
B13
B3
B1
R53
B2
C12
DZ25
DZ23
R36
R29
DZ22
C9
D14
R30
D15 R34
C19 R35
R31
R50
R51
R49
DZ26 DZ24 R1
B11 R54
B11 C11 R3
T4
R27
R2 B16 B16
DZ17
DZ3
R60
T3 R61
D4
DZ11
DZ1
R67
R58
R45
R8
D5
D2
C38
DZ4
R55
DZ9
R59
R47
DZ12
C15
R16
R15
DZ10
D3
R48
R18
R17
OCI1
C16
B12 D1
R52 B12 B5 B5
DZ2
R46
C14
R14
R13
X1
J37
R12
C13
R11
C21
C18 C40
B8
D12
D13
B8
C25
T5
B6
C17
L2 C33
B56 B56
C23
B7
B20
B58
L4
R81 B7
B6
B58 R79
D11
R80
X2
B57
B57
D10
R78
B18 B17 B17
B23
C24
C20
S500 POWER
LED2
FTP1
B18
G6846-1
R28
DZ21
C36 C2 DZ19
R39
R6
R37
C22
DZ18
D16
R9
C1
R68
R32
B10 B4
R38
R4
R63
B10 B4
D7
C4
R5
J36
R10
R69
DZ20
D17
R33
DZ15
R20
DZ5
R40
C39
C3
C7 R21
R22
C8
B9 B15
R62
R44
B9 D6
B15
R19
T2
R43
DZ6
DZ16
B44
R72
R65 DZ14
R73
B55
LED1
D9 R42
R25
D8
R64
DZ13 T1 DZ8 R26

C37
XXXX DZ7
C6
T6
C5
R24
R41 R23
L1
R77
R76
C34
J35 J34
POWER WAVE® S500


FIGURE F.12 – POWER CONVERSION ASSEMBLY VOLTAGE CHECK TEST POINTS
LED 4 J33 B28 LED 3 B29
J32 J33
B28 L3 B29
R74
R75
C35
R70
R66
R7
LED4
R71
LED3
LED5 XXXX FTP3 B13
LED 5 C10
B3
B1
R53
B2
C12
DZ25
DZ23
R36
R29
DZ22
C9
D14
R30
D15 R34
C19 R35
R31
R50
R51
R49
DZ26 DZ24 R1
R54 R27
B11 C11 R3
T4 R2 B16
DZ17
DZ3
R60
T3 R61
D4
DZ11
DZ1
R67
R58
R45
R8
D5
D2
C38
DZ4
R55
DZ9
R59
R47
DZ12
C15
R16
R15
DZ10
D3
R48
R18
R17
OCI1
C16
D1
R52 B12 B5
DZ2
R46
C14
R14
R13
X1
J37
J37
R12
C13
R11
C21
C18 C40
D12
D13
B8
C25
T5
C17
L2 C33
B56
C23
B20
B58
L4
R81 B7
B6 X2
D11
R80
R79
B57
D10
R78
B18 B17 B17
B23
C24
C20
S500 POWER
LED2
FTP1
G6846-1
R28
DZ21
C36 C2 DZ19
LED 2
R39
R6
R37
C22
DZ18
D16
R9
C1
R68
R32
R38
R4
R63
B10 B4
D7
C4
R5
B18
J36
R10
R69
DZ20
D17
R33
DZ15
R20
DZ5
R40
C39
C3
C7 R21
R22
C8
R62
R44
B9 D6
B15
R19
T2
R43
DZ6
DZ16
B44
R72
R65 DZ14
R73
B55
LED1
LED 1
D9 R42
R25
D8
R64
DZ13 T1 DZ8 R26

C37
XXXX DZ7
C6
T6
C5
R24
R41 R23
L1
R77
R76
C34
J35 J34
J34 PIN 1 PIN 6

PIN 13
PIN 4 PIN 9
J33
J34
J37 PIN 4
PIN 10 PIN 14
POWER WAVE® S500


TABLE F.12 – POWER CONVERSION LED LEGEND
LED NUMBER DESCRIPTION CONDITIONS LED STATUS

LED 1 BOTTOM BOOST INPUT POWER OFF
IGBT DRIVE (472VAC) APPLIED
AND MACHINE “ON”
LED 2 BOTTOM BUCK INPUT POWER ON
LED 3 TOP BUCK INPUT POWER ON
LED 4 TOP BOOST INPUT POWER OFF

LED 5 +48VDC AUXILIARY INPUT POWER ON
(472VAC) APPLIED
LED NUMBER DESCRIPTION CONDITIONS LED STATUS

LED 1 BOTTOM BOOST INPUT POWER ON
LED 2 BOTTOM BUCK INPUT POWER ON
LED 3 TOP BUCK INPUT POWER ON

LED 4 TOP BOOST INPUT POWER ON
LED 5 +48VDC AUXILIARY INPUT POWER ON
(255VAC) APPLIED
POWER WAVE® S500


TABLE F.13 – POWER CONVERSION ASSEMBLY VOLTAGE TESTS

READING
INPUT TO TOP B29(+) B28(–) 635VDC 472VAC INPUT AND
BUCK/BOOST MACHINE “ON”
CIRCUIT
INPUT TO BOTTOM B17(+) B18(–) 635VDC 472VAC INPUT AND
CIRCUIT
OUTPUT OF J33 PIN 1 (+) J33 PIN 10 (–) 402VDC 472VAC INPUT AND
CIRCUITS
SUPPLY FOR THE J33 PIN 6 (+) J33 PIN 10 (–) +15VDC 472VAC INPUT AND
TOP BUCK/BOOST MACHINE “ON”
LEM
SUPPLY FOR THE J33 PIN 14 (+) J33 PIN 10 (–) –15VDC 472VAC INPUT AND
TOP BUCK/BOOST MACHINE “ON”
LEM
BOTTOM BUCK / MACHINE “ON”
BOOST LEM
SUPPLY FOR THE J34 PIN 4 (+) J33 PIN 10 (–) –15VDC 472VAC INPUT AND
BOTTOM BUCK / MACHINE “ON”
BOOST LEM
DC BUS BOARD MACHINE “ON”
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-38
MULTI-PHASE OUTPUT CHOKE TEST

WARNING
manual.
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
POWER WAVE® S500

MULTI-PHASE OUTPUT CHOKE TEST (continued)

FIGURE F.13 – TEST COMPONENT LOCATIONS
MULTI-PHASE
OUTPUT CHOKE
MULTI-PHASE
CHOPPER BOARD
NEGATIVE
BUSS BAR
PROCEDURE
5. Using a 7/16” wrench, label and remove leads
WARNING BL1, BL2, BL3, BL4, BL5 and BL6 from the
Chopper Board. Save the bolts and lock wash-
ELECTRIC SHOCK can kill. ers for reassembly. See Figure F.14. See
Wiring Diagram.
parts or electrodes with your 6. Label and remove the six Output Choke leads
skin or wet clothing. from the negative bus bar located near the left
side front of the machine. See Figure F.13.
• Insulate yourself from the work and ground. Note the choke leads are connected in pairs.
• Always wear dry insulating gloves. The same lead pairs must be reconnected to
each other on the bus bar. See the Wiring
------------------------------------------------------------------- Diagram.
1. Remove the input power to the Power Wave® 7. Check the continuity of each of the individual
S500 machine. 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 con-
3. Locate the Multi-Phase Chopper Board located tinuity to each other. See the Wiring Diagram.
on the lower right side of the machine. See
Figure F.13.
POWER WAVE® S500

MULTI-PHASE OUTPUT CHOKE TEST (continued)

FIGURE F.14 – MULTI-PHASE OUTPUT CHOPPER BOARD LEAD LOCATIONS
R75 R3 R47
R74
C16
C15
X15
BL6
BL6
C24
D15
D115
DZ18
R76
OCI5
D13
FTP4
R77
R44
R2
R43
C17
R29
FTP-5V
J104
C26
BL5
BL5
L9
D116
FTP5
FTP15V
G6870-1
L1
R79 R78
FTP6
R1
R34
X16
C25
BL4
FTP1
J103
BL4
D117
C27
R45
R46
D111
DZ16
FTP2
R69
DZ17
R6
R66
R67
D112 R68
C58
D118
D119
BL3
J102
BL3
C57
X17
FTP3
C59
C65
MULTIPHASE CHOPPER
R65
C60
R70
FTP+3.3V
C64
R71 C74
R5
X19
D120
FTP_GND
BL2
BL2
C63
J101
D113
J41
R73 R72
R4
BL1
BL1
D114
LED1
R9
J42
R8
R7
B2
B1
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.
Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-42
CURRENT TRANSDUCER TEST

WARNING
manual.
TEST DESCRIPTION
This test will help determine if the Current Transducers are receiving the correct input volt-
ages 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
POWER WAVE® S500

CURRENT TRANSDUCER TEST (continued)

FIGURE F.15 – CURRENT TRANSDUCER TEST COMPONENT LOCATIONS
MULTI-PHASE
OUTPUT CHOKE
ASSEMBLY
CURRENT TRANSDUCER
OUTPUT CONTROL
FEEDBACK
CURRENT TRANSDUCER
MULTI-PHASE CHOPPER
FEEDBACK
PROCEDURE
4. Locate plug J8 on the Digital Control Board.
WARNING See Figure F.16. See Wiring Diagram.
5. Locate plug J42 on the Mult-Phase Chopper
ELECTRIC SHOCK can kill. Board. See Figure F.17. See Wiring Diagram.
• Do not touch electrically live 6. Carefully apply the correct input power to the
parts or electrodes with your Power Wave® S500.
7. To check for the correct supply voltages per-
• Insulate yourself from the work and ground. form the voltage checks on Table F.14.
• Always wear dry insulating gloves. NOTE: Do not attempt to check the voltages at the
------------------------------------------------------------------- current transducersʼ connectors. The ter-
minals are small and delicate and may be
1. Remove the input power to the Power Wave® damaged if probed with meter leads.
S500 machine.

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


FIGURE F.16 – DIGITAL CONTROL BOARD TEST POINTS
PIN 1 PIN 4
J8
J8
PIN 5 PIN 8
DZ1
DZ2
D1 D3
D47
D46
D45
D44
Q3 Q6
D7
D9
J5 J6 J7 J8 J9
D19
DZ7
DZ6
D22
D4 D6
DZ8
D8 X100
LED1
LED2
X26
D10
D11
Q1 D17
J3
D2 D5 X11
DZ3
DZ4
X8
X94 X96 X95 X97
D16
DZ5
X5 X9 X10
L2
X79
X4
X99 X24
C6
L1
Q24 X93 X98 C8
OCI2
X15
X13
X22
X40
Q11 Q14
Q25 X75 Q31 X38 X21
X18 X19
X39
X20
FTP8
FTP6
O O
N N
X14
S3 S1
OCI1
FTP7
Q10 X41 X25 X36 X85 X12
J12
L6
LED3
LED6
X33 C110 Q16 X34
X83 X82 X29 X28
LED4
LED5
L8
C325
FTP4
FTP5
L14
Y1 X92
X32
X81
L5
L13
L4
FTP2
R510 X35
BT1
Y2 FTP1
R6
X50
X47
D54
R12
X46 R21 X51
X48
FTP3
D55
X52
L7
R15
X49
LED9 C9 C10 CT1
X78
C255
LED8
T1
Y3 X63
X62 Q20 C11 C12
J15
X53 R24
X61
L9
LED7
D30
X77
Q18
X65
X1
L10
OCI7 OCI8 L11 L12
DIGITAL CONTROL
X58
T2
G6682-1
DZ31 DZ32
OCI10 OCI9 C14
X54
Q19
X60
O X59 C13
Q21
N D38 D39 D40 D41

S2 OCI5 OCI6
D37
C17
C15 X64
D35 X68 Q22 Q23
C19 C22
LED10
X67
D42
DZ24
DZ23
D43
C18 C20
X70
J13 J2 J4 X72 X73 X74
J11
C287
C252
X57 C21
X69
X71
C292
OCI12
For the following steps refer to the information 11. Check the current transducersʼ feedback volt-
in the Diagnostic Utility found at ages. See Table F.15.
Powerwavemanager.com.
12. Repeat the test at several other current levels.
8. Using a Ethernet Cross Connect cable, connect If the transducersʼ feedback voltagesʼ are cor-
a laptop computer to the Power Wave® S500 via rect for the actual current, the transducers are
the Ethernet port located at the top rear of the functioning properly. If there is no feedback
machine. check the connections between the current
transducers and the PC boards. See the
9. Connect a resistive load bank (or 50 Ft. weld
Wiring Diagram.
cable) to the positive and negative output termi-
nals on the Power Wave® S500 machine.
CAUTION
10. Using the Diagnostic Utility Software:
Establish communications with the Power If using a weld cable across the output termi-
Wave® S500. nals instead of a resistive load bank, do not
exceed the current rating of the cable.
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.
POWER WAVE® S500


FIGURE F.17 – MULTI-PHASE CHOPPER BOARD TEST POINTS
R75 R3 R47
R74
C16
C15
X15
BL6
C24
D15
D115
DZ18
R76
OCI5
D13
FTP4
R77
R44
R2
R43
C17
R29
FTP-5V
J104
C26
BL5
L9
D116
FTP5
FTP15V
G6870-1
L1
R79 R78
FTP6
R1
R34
X16
C25
FTP1
J103
BL4
D117
C27
R45
R46
D111
DZ16
PIN 3 PIN 1
FTP2
R69
DZ17
R6
R66
R67
D112 R68
C58
J42
D118
D119
J102
PIN 4 PIN 2
BL3
C57
X17
FTP3
C59
C65
MULTIPHASE CHOPPER
R65
C60
R70
FTP+3.3V
C64
R71 C74
R5
X19
D120
FTP_GND
BL2
C63
J101
D113
J41
R73 R72
R4
BL1
D114
LED1
R9
J42
J42
R8
R7
B2
B1
13. If the supply voltages are correct per Table

F.14 but the transducersʼ 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.
S500 machine.
Procedure.
POWER WAVE® S500


TABLE F.14 – CURRENT TRANSDUCERS SUPPLY VOLTAGE CHECKS

READING
SUPPLY VOLTAGE J42 PIN 1 LEAD 216 J42 PIN 4 LEAD 218 +15VDC MACHINE “ON”
TO MULTI-PHASE
CHOPPER
TRANSDUCER
SUPPLY VOLTAGE J42 PIN 2 LEAD 217 J42 PIN 4 LEAD 218 –15VDC MACHINE “ON”
TO MULTI-PHASE
CHOPPER
TRANSDUCER
SUPPLY VOLTAGE J8 PIN 2 LEAD 212 J8 PIN 6 LEAD 214 +15VDC MACHINE “ON”
TO OUTPUT
CONTROL
TRANSDUCER
SUPPLY VOLTAGE J8 PIN 3 LEAD 213 J8 PIN 6 LEAD 214 –15VDC MACHINE “ON”
TO OUTPUT
CONTROL
TRANSDUCER
POWER WAVE® S500


TABLE F.15 – CURRENT TRANSDUCERS FEEDBACK VOLTAGE CHECKS
MULTI-PHASE CHOPPER TRANSDUCER
OUTPUT CURRENT TEST POINT TEST POINT EXPECTED

(AMPS) READING
500 J42 PIN 3 LEAD 215 J42 PIN 4 LEAD 218 4.0VDC
OUTPUT CONTROL TRANSDUCER
OUTPUT CURRENT TEST POINT TEST POINT EXPECTED

(AMPS) READING

POWER WAVE® S500

40 VOLT DC BUS BOARD TEST

WARNING
manual.
TEST DESCRIPTION
This test will help determine if the 40 Volt DC Bus Board is receiving the correct input volt-
age and if the board is functioning correctly.
MATERIALS NEEDED
Volt/Ohmmeter
Wiring Diagram
POWER WAVE® S500

40 VOLT DC BUS BOARD TEST (continued)

FIGURE F.18 – 40 VOLT DC BUS BOARD LOCATION

40 VOLT DC
BUS BOARD
PROCEDURE
6. If the red LED is lit, the DC Bus Board is receiv-
WARNING
ing 48VDC voltage from the Power Conversion

Assembly.
ELECTRIC SHOCK can kill. 7. If the red LED is blinking, carefully remove plug
• Do not touch electrically live J47 from the DC Bus Board. See Figure F.19.
parts or electrodes with your If the blinking stops and the red LED stays lit
skin or wet clothing. and steady, this is an indication of a heavy load
on the 40VDC output line. See the Wiring
• Insulate yourself from the work and ground. 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.
9. Perform the voltage tests per Table F.16. See
1. Remove the input power to the Power Wave® Figure F.19.
S500 machine.
10. If the correct input voltage is being applied to
2. Perform the Case Cover Removal and the DC Bus Board and the correct output volt-
Capacitor Discharge Procedure. ages are not being generated, the DC Bus
3. Locate the DC Bus Board located on the lower Board is faulty.

right side of the machine. See Figure F.18. 11. If faulty, perform the 40 Volt DC Bus Board
4. Carefully apply the correct input power to the Removal and Replacement Procedure.
Power Wave® S500 machine. 12. Perform the Case Cover Replacement
5. Locate the red LED on the DC Bus Board. See Procedure.
Figure F.19. See Wiring Diagram. 13. Perform the Retest After Repair Procedure.
POWER WAVE® S500

40 VOLT DC BUS BOARD TEST (continued)

FIGURE F.19 – 40 VOLT DC BUS BOARD TEST POINTS
LEAD
LEAD #52A
LEAD LEAD
#52 RED #66 #65A
LED
LEAD J47
#51A
J48
LEAD
#51
L15732-1
TABLE F.16 – 40 VOLT DC BUS BOARD TEST POINTS AND EXPECTED READINGS
DESCRIPTION TEST POINT TEST POINT EXPECTED

READING
INPUT FROM THE PLUG J48 PIN 1 (+) PLUG J48 PIN 3 (–) 48VDC
POWER CONVERSION LEAD #65A LEAD #66
ASSEMBLY
40VDC OUTPUT TO PLUG J47 PIN 8 (+) PLUG J47 PIN 1 (+) 40VDC
ArcLink RECEPTACLE LEAD #52A LEAD #51A
40VDC OUTPUT TO PLUG J47 PIN 4 (+) PLUG J47 PIN 5 (+) 40VDC
PFC CONTROL BOARD LEAD #52 LEAD #51
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-52
INPUT BOARD TEST

WARNING
manual.
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
POWER WAVE® S500

INPUT BOARD TEST (continued)

FIGURE F.20 – INPUT BOARD LOCATION
INPUT
BOARD
PROCEDURE
WARNING 5. Locate the Green LED on the Input Board. See
Figure F.21. See Wiring Diagram.
ELECTRIC SHOCK can kill. 6. Carefully apply the correct three phase input
power to the Power Wave® S500 machine.
parts or electrodes with your 7. If the Green LED is lit, the Input Board is receiv-
skin or wet clothing. ing input power. See Figure F.21.
• Insulate yourself from the work and ground. 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
S500 machine.
the Input Board and the correct output voltages
2. Perform the Case Cover Removal and are not being generated the Input Board may
Capacitor Discharge Procedure. be faulty.
3. Locate the Input Board located on the upper 11. If faulty, perform the Input Board Removal
right side of the machine. See Figure F.20. and Replacement Procedure. Be sure to
replace the insulating cover on the Input Board.

NOTE: To gain access to the Input Board the insu-
lating cover will have to be removed. Cut 12. Perform the Case Cover Replacement
the three cable ties securing the insulating Procedure.
cover.
13. Perform the Retest After Repair.
4. Perform the Input Board diode checks per
Table F.17 and Figure F.21.
POWER WAVE® S500


TABLE F.17 – INPUT BOARD DIODE CHECKS

SMALL 3-PHASE B1 J1 PIN 3 ON BOARD .578V
RECTIFIER PLUG REMOVED
SMALL 3-PHASE J1 PIN 3 ON BOARD B1 OPEN

LARGER 3-PHASE B1 B4 .511V
BRIDGE
BRIDGE
BRIDGE
LARGER 3-PHASE B4 B1 OPEN
BRIDGE
BRIDGE
BRIDGE
BRIDGE
BRIDGE
BRIDGE
BRIDGE
BRIDGE
BRIDGE
POWER WAVE® S500


FIGURE F.21 – INPUT BOARD TEST POINT LOCATION
10 6
J1 J1
5 1
R6 R3 R7
J1
C1
C2
D7
R5
GREEN
D2
C3
CR1
D1
D3
LED
R4
LED1
B3
B3
B4
B4
R8
R11
A1
B5
D5
B2
B2
R10
D6
CR2
M22489-2
INPUT
D4
R9
B1
R1
R2
B1
B5
TABLE F.18 – INPUT BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS
(NOMINAL 460VAC APPLIED)

READING
THREE-PHASE INPUT B1 B2 AC LINE VOLTAGE
(Ex. 470VAC)
(Ex. 470VAC)
(Ex. 470VAC)
DC TO POWER B4(+) B5(–) AC LINE VOLTAGE X
CONVERSION BOARD 1.414 +/–10%
(Ex. 629VDC)
FILTERED DC TO PLUG J1 PIN 6 B5(–) AC LINE VOLTAGE X
PFC BOARD (LEAD 366) (+) 1.414 +/–10%
(Ex. 648VDC)
RECTIFIED AC TO PLUG J1 PIN 3 B5(–) AC LINE VOLTAGE X

PFC BOARD (LEAD 369) (+) 1.414 +/–10%
(Ex. 629VDC)
DC POWER TO RELAYS PLUG J1 PIN 10 PLUG J1 PIN 5 15VDC
CR1 AND CR2 FROM (LEAD 362) (+) (LEAD 367) (–)
PFC BOARD
POWER WAVE® S500

MULTI-PHASE CHOPPER BOARD TEST

WARNING
manual.
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
POWER WAVE® S500

MULTI-PHASE CHOPPER BOARD TEST (continued)

FIGURE F.22 – MULTI-PHASE CHOPPER BOARD LOCATION

MULTI-PHASE
CHOPPER BOARD
PROCEDURE
4. Perform the Multi-Phase Chopper Board diode
WARNING checks per Table F.19 and Figure F.23.
5. Locate the Green LED on the Multi-Phase
ELECTRIC SHOCK can kill. Chopper Board. See Figure F.23. See Wiring
• Do not touch electrically live Diagram.
parts or electrodes with your 6. Carefully apply the correct three phase input
skin or wet clothing. power to the Power Wave® S500 machine.
• Insulate yourself from the work and ground. 7. If the Green LED is lit, the Multi-Phase Chopper
• Always wear dry insulating gloves. Board is receiving input power from the Power
Conversion Assembly (100VDC). See Figure
------------------------------------------------------------------- F.23.
1. Remove the input power to the Power Wave® 8. If the Green LED is not lit, the Multi-Phase
S500 machine. Chopper Board may not be receiving the

100VDC from the Power Conversion Board.
2. Perform the Case Cover Removal and See the Wiring Diagram.
3. Locate the Multi-Phase Chopper Board located
on the lower right side of the machine. See
Figure F.22.
POWER WAVE® S500


FIGURE F.23 – MULTI-PHASE CHOPPER BOARD TEST POINTS
R75 R3 R47
R74
C16
C15
X15
BL6
BL6
C24
D15
D115
DZ18
R76
OCI5
D13
FTP4
R77
R44
R2
R43
C17
R29
FTP-5V
J104
C26
BL5
BL5
L9
D116
FTP5
FTP15V
G6870-1
L1
R79 R78
FTP6
R1
R34
X16
C25
BL4
FTP1
J103
BL4
D117
6 LEDS
C27
R45
R46
D111
DZ16
(GATE FIRING)
FTP2
R69
DZ17
R6
R66
R67
D112 R68
C58
D118
D119
BL3
J102
BL3
C57
X17
FTP3
C59
C65
MULTIPHASE CHOPPER
R65
C60
R70
FTP+3.3V
C64
R71 C74
R5
X19
D120
FTP_GND
BL2
BL2
C63
J101
D113
J41
R73 R72
R4
BL1
BL1
D114
LED1
GREEN LED
R9
J42
R8
R7
B2 B1
B2
B1
9. Energize the output of the Power Wave® S500 11. If the correct input voltage is being applied to
machine. Check to make sure the six LEDs on the Multi-Phase Chopper Board and the correct
the Multi-Phase Control board are lit. This is an output voltages are not being generated, the
indication that the Multi-Phase Control board is Multi-Phase Chopper Board may be faulty.
receiving gate firing signals from the Control
12. If faulty, perform the Chopper Board Removal
Board and the Multi-Phase board is providing
and Replacement Procedure.
gate driving signals to the Multi-Phase Chopper
board. See Figure F.23. 13. Perform the Case Cover Replacement
Procedure.
10. Carefully perform the voltage tests per Table
F.20. See Figure F.23. 14. Perform the Retest After Repair Procedure.
POWER WAVE® S500


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 TEST POINT TEST POINT CONDITIONS EXPECTED

METER PROBE (+) METER PROBE (–) READING +/–10%
PHASE 3 DRIVER B2 BL1 ALL LEADS .413V
REMOVED FROM
B1 AND B2
REMOVED FROM
B1 AND B2
REMOVED FROM
B1 AND B2
REMOVED FROM
B1 AND B2
REMOVED FROM
B1 AND B2
REMOVED FROM
B1 AND B2
POWER WAVE® S500


TABLE F.20 – MULTI-PHASE CHOPPER BOARD VOLTAGE TEST POINTS AND EXPECTED READINGS
MODE OPEN CIRCUIT TEST POINT (+) TEST POINT (–) EXPECTED
VOLTAGE READING (+/–10%)
TIG 24VDC B1 B2 97VDC
TIG 24VDC BL1 B2 73VDC
CV 70VDC B1 B2 97VDC
CV 70VDC BL1 B2 26VDC
STICK 60VDC B1 B2 97VDC
STICK 60VDC BL1 B2 36VDC

POWER WAVE® S500


NOTES
POWER WAVE® S500

F-62
CURRENT AND VOLTAGE CALIBRATION PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will aid the technician in checking and if necessary, adjusting the calibra-
tion of the Power Wave® S500.
Calibration should be checked as part of the Retest After Repair Procedure.
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 perfor-
mance. Use good quality digital meters that are calibrated and traceable to
National Standards.
POWER WAVE® S500

CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued)

CALIBRATION SET-UP CALIBRATION PROCEDURE:

1. Once in the “Calibration” screen, make sure
WARNING that the machine output is OFF (light is BLACK)
and connect a resistive load bank to the output
ELECTRIC SHOCK can kill. studs.
• Do not touch electrically live 2. Set the load bank for 300 Amps.
parts or electrodes with your 3. On the Calibration screen, select the 300 Amps
skin or wet clothing. Current Set Point.
• Insulate yourself from the work and ground. NOTE: If the meters on the load bank are not cer-
• Always wear dry insulating gloves. tified, connect calibrated and traceable
meters to the machine output. (See

------------------------------------------------------------------- Materials Needed at the beginning of this
Section).
1. Load the Power Wave Manager Utility Software
into the computer. WARNING
2. Use the Ethernet cable to connect the comput-
er to the Power Wave® S500. The Output Studs of the Machine will be
3. Connect a resistive load bank to the output Electrically “HOT” during Steps 4 thru 7.
studs.
-------------------------------------------------------------------
4. Energize the Power Wave® S500.
4. Click on the “Turn Output ON” button. The
5. Launch the Power Wave Manager Utility and BLACK light on the screen will flash RED indi-
establish communication with the Power Wave® cating that the weld output is turned ON. See
S500 (Refer to the Software Documentation to Figure F.24.
determine proper connection).
5. Adjust the load bank to 300 Amps at approxi-
6. Click on the “Calibration” Tab. A screen similar mately 32 Volts as read on the external cali-
to Figure F.24 should appear and you are ready brated meters.
to begin the calibration check.
6. Using the “Calibration Adjustment” buttons:
NOTE: The Calibration Screen may look Adjust the current so that the external ammeter
slightly different depending on the reads 300 Amps +/-2A. Adjust the voltage so
Software version. that the “Output Voltage” display window reads
the same as the external voltmeter +/-.3 volts.
Calibration can only be done under
“Static Load” conditions. Do not 7. Click on the “Turn Output OFF” button.
Calibration is complete. (Also check at 300
attempt to calibrate while welding. Amps + 50 Amps).
NOTE: Incorrect calibration can and will affect
welding performance. It is strongly recom-
mended 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).
POWER WAVE® S500

CURRENT AND VOLTAGE CALIBRATION PROCEDURE (continued)

FIGURE F.24 – CALIBRATION SCREEN

POWER WAVE® S500


NOTES
POWER WAVE® S500

F-66
PFC CONTROL BOARD

REMOVAL AND REPLACEMENT PROCEDURE
WARNING
manual.
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
POWER WAVE® S500

PFC CONTROL BOARD

REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.25 – PFC CONTROL BOARD LOCATION
PFC CONTROL
BOARD
PFC BOARD
MOUNTING PANEL
FRONT PANEL
ASSEMBLY
REMOVAL PROCEDURE
3. Locate the PFC Control Board. See Figure
WARNING F.25.
4. Label and remove plugs J20, J21, J22, J23A,
ELECTRIC SHOCK can kill. J23B, J24, J25 and J26. See Figure F.26. See
• Do not touch electrically live Wiring Diagram.
parts or electrodes with your 5. Using a 3/8” wrench, remove the four nuts
skin or wet clothing. securing the PFC Control Board to the PFC
• Insulate yourself from the work and ground. board mounting panel. See Figure F.25.
• Always wear dry insulating gloves. 6. Carefully remove the PFC Control Board from
the mounting studs. Cut any cable ties that
------------------------------------------------------------------- may inhibit the removal.
1. Remove input power to the Power Wave® S500

machine.
2. Perform the Case Cover Removal and DC
Link Capacitor Discharge Procedure.
Remove the right and left side case covers.
POWER WAVE® S500

PFC CONTROL BOARD


FIGURE F.26 – PFC CONTROL BOARD PLUG LOCATIONS
J23A J23B
FTP25
C4 C6
FTP27
J23A FTP9 FTP7 J23B
R7
R8
R3
R4
D9 D11
D17
D8
D22
D21
D5 D6 D7 C5 D18 D19 D20
D2
D1
C7 Q10
T1
FTP19
FTP8 X7
FTP28
X1
C8
C9
X2 X3 D10 D12 X5 X6 Q1
C2
C3
D23
D24
D3
D4
Q9
Q2
FTP16
C20
D14
D16
C12
C1 X4 C10
DZ1
DZ2
DZ3
DZ4
DZ5
DZ6
DZ7
DZ8
C11
C24
C25
C23
C21
D13
D15
X8 X12
D25
L1
OCI1 OCI2 OCI3 OCI4

D28 D29
J24
D43
D44
J24
FTP23 X18 X19 X17 X16 R257
D26 D27
R65
C13 C14
DZ10
FTP20
C19
Q4
FTP21
D45
D46
D47
D48
C35
Y2
D30
D31
D41
D42
D39
D40
X31 FTP5
C15
X13 X14
C17
LED2
1
FTP35
FTP37
FTP36
FTP33
FTP34
LED5
C27
C26
J2
FTP14
FTP4
Y1
FTP26
FTP13
C22
C16
FTP31 FTP32
FTP15 1 J1 X20
X22
D52
D53
D54
D55
DZ9
X21
Q3 D49 FTP6
X24
J25
FTP38
FTP10
J25
C74
R56
R57
FTP24
X10
LED1
X26 OCI5
FTP12
FTP18
FTP22
C39
R92
DZ11
R86
FTP11
J22 X25
J22
C66
R91
FTP2
DZ12
DZ17
FTP30
DZ18
R110
X27
LED3
FTP1
D36 D33 D35 D38 D34 D37
R84
D51
FTP17
D64
DZ19 D56
D58
X9 C30
D50
C29 Q8
D57 C31
J21
DZ20
FTP29 FTP40
J21
D62
D59
D68
D65
D63
X29 X30 Q7
T2
J26
D61
J26
D60
J20
DZ22
J20
C32
R2
D67 D66
C33
Q6
C34
G6860-1
R210
R209
R212
LED4
D69
FTP3
MOUNTING STUDS
AND NUTS
(4 PLACES)
1. Place the new PFC Control Board onto the
mounting studs.
2. Using a 3/8” wrench, attach the four nuts secur-
ing 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.
Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-70
115 VOLT SUPPLY BOARD

WARNING
manual.
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
POWER WAVE® S500



FIGURE F.27 – 115 VOLT SUPPLY BOARD LOCATION
115 VOLT
SUPPLY BOARD
REMOVAL PROCEDURE
3. Locate the 115 Volt Supply Board. See Figure
WARNING F.27.
4. Label and remove plugs J82 and J83. It is not
ELECTRIC SHOCK can kill. necessary to remove plug J81. See Figure
• Do not touch electrically live F.28. See Wiring Diagram.
parts or electrodes with your 5. Label and disconnect the leads connected to
skin or wet clothing. tab terminals B5 and B6. See Figure F.28.
• Insulate yourself from the work and ground. See Wiring Diagram.
• Always wear dry insulating gloves. 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.
1. Remove input power to the Power Wave® S500 7. Carefully remove the 115 Volt Supply Board
machine. from the mounting studs. Cut any cable ties

that may inhibit the removal.
Remove the right side case cover.
POWER WAVE® S500



FIGURE F.28 – 115 VOLT SUPPLY BOARD LEAD LOCATIONS
J83
J82
J82 J83
LED 3
LED 2
NUTS
LED 1
(4 PLACES)
J81
B6
B5
J81
B5 B6
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 ter-
minals B5 and B6. See Wiring Diagram.
5. Replace any cable ties that may have been
removed.

Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-74
40 VOLT DC BUS BOARD

WARNING
manual.
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
POWER WAVE® S500



FIGURE F.29 – 40 VOLT DC BUS BOARD LOCATION
40 VOLT DC
BUS BOARD
REMOVAL PROCEDURE
3. Locate the 40 Volt DC Bus Board. See Figure
WARNING F.29.
4. Locate and remove plugs J46 and J47. See
ELECTRIC SHOCK can kill. Figure F.30. See Wiring Diagram.
• Do not touch electrically live 5. Using a 3/8” nutdriver, remove the four nuts
parts or electrodes with your securing the 40 Volt DC Bus Board to the front
skin or wet clothing. divider panel. See Figure F.30.
• Insulate yourself from the work and ground. 6. Carefully remove the 40 Volt DC Bus Board
• Always wear dry insulating gloves. from the mounting studs.
-------------------------------------------------------------------

machine.
POWER WAVE® S500



FIGURE F.30 – 40 VOLT DC BUS BOARD MOUNTING NUT AND LEAD LOCATIONS
LED 1
LED1
J46
J47
J46
J47
NUTS NUTS
(4 PLACES) (4 PLACES)
L15732-1
1. Place the new 40 Volt DC Bus Board onto the
mounting studs.
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.
Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-78
LINE SWITCH
WARNING
manual.
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
POWER WAVE® S500

LINE SWITCH

FIGURE F.31 – LINE SWITCH LOCATION
LINE SWITCH
LINE SWITCH
COVER
REMOVAL PROCEDURE
3. Locate the Line Switch. See Figure F.31.
WARNING
4. Using a 5/16” nutdriver, remove the two screws
securing the Line Switch to the front panel. See
ELECTRIC SHOCK can kill. Figure F.31.
• Do not touch electrically live 5. Carefully remove the Line Switch from the front
parts or electrodes with your panel and slide it to the right side to gain access
skin or wet clothing. to the leads. Remove the electrical tape and
• Insulate yourself from the work and ground. take note of the line switch cover for reassem-
bly.
6. Using a slotted screwdriver, label and remove
------------------------------------------------------------------- leads L4A, L5A and L6A from the Line Switch.
See the Wiring Diagram.
machine. 7. Using a slotted screwdriver, label and remove

leads L4, L5 and L6 from the Line Switch. Take
2. Perform the Case Cover Removal and DC note of the MOV assembly for reassembly. See
Link Capacitor Discharge Procedure. the Wiring Diagram.
8. Remove the Line Switch.
POWER WAVE® S500

LINE SWITCH
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.
Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-82
INPUT BOARD
WARNING
manual.
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
POWER WAVE® S500

INPUT BOARD

FIGURE F.32 – INPUT BOARD LOCATION
INPUT
BOARD
REMOVAL PROCEDURE
4. Carefully remove the input board cover. Cut the
WARNING three cable ties holding the input board cover in
place.
ELECTRIC SHOCK can kill. 5. Label and remove plug J1 from the Input Board.
• Do not touch electrically live See Figure F.33. See Wiring Diagram.
parts or electrodes with your 6. Using a 7/16” wrench, label and remove leads
skin or wet clothing. B1, B2 and B3 from the Input Board. See
• Insulate yourself from the work and ground. Figure F.33. See Wiring Diagram.
• Always wear dry insulating gloves. 7. Using a 7/16” wrench, label and remove leads
B4 and B5 from the Input Board. See Figure
------------------------------------------------------------------- F.33. See Wiring Diagram.
1. Remove the input voltage from the Power 8. Using a 3/8” nutdriver, remove the four nuts
Wave® S500 machine. securing the Input Board to the mounting posts.
See Figure F.33.
3. Locate the Input Board. See Figure F.32.
POWER WAVE® S500

INPUT BOARD

FIGURE F.33 – INPUT BOARD LEAD LOCATIONS
J1
R6 R3 R7
J1
C1
C2
D7
R5
D2
C3
CR1
D1
D3
R4
LED1
B3
B3
MOUNTING
B4
B4
NUTS
R8
R11
A1
(4)
B5
D5
B2
B2
R10
D6
CR2
M22489-2
INPUT
D4
R9
B1
R1
R2
B1
B5
1. Position the new Input Board and heat sink
assembly onto the four mounting posts.
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.
Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-86
DIGITAL CONTROL BOARD

WARNING
manual.
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
POWER WAVE® S500



FIGURE F.34 – DIGITAL CONTROL BOARD LOCATION
DIGITAL CONTROL
BOARD
REMOVAL PROCEDURE
4. Locate the Digital Control Board. See Figure
WARNING F.34.
5. Label and remove plugs J5, J6, J7, J8, J9, J12,
ELECTRIC SHOCK can kill. J11 and J14. See Figure F.35. See Wiring
• Do not touch electrically live Diagram.
parts or electrodes with your 6. Label and remove the Ethernet cable from the
skin or wet clothing. board. See Wiring Diagram.
• Insulate yourself from the work and ground. 7. Using a 3/8” nutdriver, remove the four nuts
• Always wear dry insulating gloves. securing the Digital Control Board to the top
case cover. See Figure F.35.
-------------------------------------------------------------------
8. Carefully remove the Digital Control Board from
1. Remove input power to the Power Wave® S500 the mounting studs.
machine.
3. Carefully lift up the top case cover.
POWER WAVE® S500



FIGURE F.35 – DIGITAL CONTROL BOARD LEAD LOCATIONS
J5 J6 J7 J8 J9
DZ1
DZ2
D1 D3
D47
D46
D45
D44
Q3 Q6
D7
D9
J5 J6 J7 J8 J9
D19
DZ7
DZ6
D22
D4 D6
DZ8
D8 X100
LED1
LED2
X26
D10
D11
Q1 D17
J3
D2 D5 X11
DZ3
DZ4
X8
X94 X96 X95 X97
D16
DZ5
X5 X9 X10
L2
X79
X4 X99 X24
C6
L1
Q24 X93 X98 C8
OCI2
X15
X13
X22
X40
Q11 Q14
Q25 X75 Q31 X38 X21
X18 X19
X39
X20
FTP8
FTP6
O O
N N
X14
S3 S1
OCI1
FTP7
Q10 X41 X25 X36 X85 X12
J12
J12
L6
LED3
LED6
C110
X33 Q16 X34

X83 X82 X29 X28
LED4
LED5
L8
C325
FTP4
FTP5
L14
X92
MOUNTING STUDS
Y1
X81
X32
MOUNTING STUDS
L5
L13
L4
FTP2
R510 X35
AND NUTS BT1

Y2
X50
R6
FTP1 AND NUTS
X47
(4) X46
R12
X48
R21 X51
D54
(4)
FTP3
D55
X52
L7
R15
X49
LED9 C9 C10 CT1
X78
C255
LED8
T1
Y3 X63
X62 Q20 C11 C12
J15
X53 R24
X61
L9
LED7
D30
X77
Q18
X65
X1
L10
OCI7 OCI8 L11 L12

X58
DIGITAL CONTROL
T2
G6682-1
DZ31 DZ32
OCI10 OCI9 C14
X54
Q19
X60
O X59 C13
Q21
N D38 D39 D40 D41

S2 OCI5 OCI6
D37
C17
C15 X64
D35 X68 Q22 Q23
C19 C22
LED10
X67
D42
DZ24
DZ23
D43
C18 C20
X70
J13 J2 J4 X72 X73 X74
J11
C287
C252
X57 C21
X69
X71
C292
OCI12
J11 J14
1. Place the new Digital Control Board onto the
mounting studs.
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.
Procedure.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-90
FAN
WARNING
manual.
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
POWER WAVE® S500

FAN

FIGURE F.36 – FAN ASSEMBLY COMPONENT LOCATIONS
BRICKWORK PANEL
MOUNTING SCREWS
(6)
FAN ASSEMBLY
MOUNTING SCREWS
(4 PER ASSEMBLY)
BRICKWORK
PANEL
FAN ASSEMBLIES
(2)
REMOVAL PROCEDURE
3. Using a screwdriver, remove the four machine
WARNING screws and associated lockwashers and flat-
washers from the Fan Assembly to be replaced.
ELECTRIC SHOCK can kill. See Figure F.36.
• Do not touch electrically live 4. Carefully remove the Fan Assembly from the
parts or electrodes with your machine and disconnect the appropriate lead
skin or wet clothing. connection plug. (J55 or J56). See the Wiring
Diagram. Cut any necessary cable ties.
-------------------------------------------------------------------

machine.
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.
POWER WAVE® S500

FAN
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 flatwash-
ers to the Fan Assembly.
5. Make sure the fan spins freely without any

obstruction.
securing the brickwork panel located at the rear
of the machine.
POWER WAVE® S500


NOTES
POWER WAVE® S500

F-94
POWER CONVERSION BOARD ASSEMBLY

WARNING
manual.
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
POWER WAVE® S500



FIGURE F.37 – POWER CONVERSION BOARD ASSEMBLY LOCATION
AIR BAFFLE
POWER CONVERSION
BOARD ASSEMBLY
REMOVAL PROCEDURE
3. Locate the Power Conversion Board Assembly.
WARNING See Figure F.37.
4. Using a 5/16” and 3/8” nutdrivers, remove the
ELECTRIC SHOCK can kill. air baffle. See Figure F.37.
• Do not touch electrically live 5. Label and remove plugs J32, J33, J34, J35, J36
parts or electrodes with your and J37 from the Power Conversion Board.
skin or wet clothing. See Figure F.38. See Wiring Diagram.
• Insulate yourself from the work and ground. 6. Using a 7/16” wrench, label and remove the
• Always wear dry insulating gloves. heavy lead B2 from terminal B56. See Figure
F.38. See Wiring Diagram. Save the bolt and
------------------------------------------------------------------- washer for reassembly. Note chokesʼ lead
placement on terminal B56.
1. Remove the input voltage from the Power
Wave® S500 machine. 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



FIGURE F.38 – POWER CONVERSION BOARD ASSEMBLY LEAD LOCATIONS
J32 J33
MOUNTING
SCREWS
(5 PLACES)
B13
B2
J32 J33 B28 L3
R74
9
R75
C35
R70
R66
R7
LED4
R71
LED3
B13
LED5
C10
FTP3
LEAD B5
R53
C12
DZ25
B2
B1
B3
DZ23
R36
R29
DZ22
C9
D14
R30
D15 R34
C19 R35
R31
R50
R51
R49
DZ26 DZ24 R1
R54 R27
B11
11 C11 R3 B16
T4 R2
DZ17
DZ3
R60
T3 R61
D4
DZ11
DZ1
R67
R58
R45
R8
D5
D2
R55
DZ4
C38
TO TOP
J37
DZ9
R59
R47
DZ12
C15
R16
R15
DZ10
D3
INPUT CHOKE
R48
R18
R17
OCI1
C16
D1
B12
R52 B5
DZ2
R46
C14
R14
R13
X1
LEAD B4
J37
R12
C13
R11
C21
C18 C40
LEAD B2
D12
D13
B8
C25
T5
C17
L2 C33 B8
B56 B56
C23
B7
B20
L4
B7
B58
R81
B6 X2
D11
R80
R79
B57
D10
B1
B18
7
R78
B23
C24
C20
S500 POWER
LED2
FTP1
TO BOTTOM
G6846-1
R28
LEAD 901C
DZ21
C36 C2 DZ19
R39
R6
R37
INPUT CHOKE
C22
DZ18
D16
R9
C1
R68
R32
R38
R4
R63
B10
HEAT SINK B4
D7
C4
R5
TERMINAL
R10
R69
DZ20
D17
R33
J36
DZ15
R20
DZ5
R40
C39
C3
C7 R21
B6
R22
C8
R44
R62
B15
B9 D6
R19
LEAD 901A T2
R43
DZ6
DZ16
R65 DZ14
R72
R73
LED1
B55
D9
B44
R42
R25
D8
R64
DZ13 T1 DZ8 R26

C37
DZ7
C6
T6
C5
R24
J36 R41 R23

L1
R77
R76
J35 J34 C34
MOUNTING
STUD WITH
NUT AND
WASHER
(1 PLACE)
J35 J34
8. Using a 7/16” wrench, label and remove the top 11. Using a 5/16” nutdriver, remove the five screws
choke leads from terminals B13 and B8. Save securing the Power Conversion Board
the bolts and lock washers for reassembly. See Assembly to the frame of the machine. See
Figure F.38. See Wiring Diagram. Figure F.38.
9. Using a 7/16” wrench, label and remove the 12. Using a 3/8” nutdriver, remove the nut and
bottom choke leads from terminals B6 and B7. washer from the mounting post Lower left hand
Save the bolts and lock washers for reassem- corner. See Figure F.38.
bly. See Figure F.38. See Wiring Diagram.
13. Clear all leads and carefully remove the Power
10. Using a 7/16” wrench, label and remove the Conversion Power Board Assembly with heat
leads B4 and B5 from the buss bars. Save the sink from the machine.
bolts, lock washers and nuts for reassembly.
See Figure F.38. See Wiring Diagram.
POWER WAVE® S500


1. Position the new Power Conversion Board 6. Attach the top choke leads to terminals B13 and
Assembly onto the mounting post. B8. See Figure F.38. See Wiring Diagram.
Torque the bolts to between 50 and 60 inch
NOTE: The top of the Power Conversion Board
pounds.
Assembly will have to be positioned into
place first. 7. Attach the two heavy leads 901C and 901A to
the heat sink terminal. See Figure F.38. See
2. Using a nut and washer previously removed,
Wiring Diagram. Torque the bolts to between
Secure the new Power Conversion Board
50 and 60 inch pounds.
Assembly onto the mounting post. See Figure
F.38. 8. Attach the heavy lead B2 to terminal B56. See
Figure F.38. See Wiring Diagram. Torque the
3. Using a 5/6” nutdriver, replace the five mounting

bolts to between 50 and 60 inch pounds. Note
screws and washers previously removed.
chokesʼ lead placement.
4. Attach leads B4 and B5 onto their respective
9. Attach plugs J32, J33, J34, J35, J36 and J37.
bus bars. See Figure F.38. See Wiring
See Figure F.38. See Wiring Diagram.
Diagram. Torque the bolts to between 50 and
60 inch pounds. 10. Attach the air baffle. See Figure F.37.
5. Attach the bottom choke leads to terminals B6 11. Clear and position all leads.
and B7. See Figure F.38. See Wiring Diagram.
Torque the bolts to between 50 and 60 inch
Procedure.
pounds.
POWER WAVE® S500

CHOPPER BOARD
WARNING
manual.
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
POWER WAVE® S500

CHOPPER BOARD

FIGURE F.39 – CHOPPER BOARD LOCATION
MULTI-PHASE
CHOPPER BOARD
REMOVAL PROCEDURE
3. Locate the Chopper Board. See Figure F.39.
WARNING
4. Locate and remove plugs J41 and J42 from the
Chopper Board. See Figure F.40. See Wiring
ELECTRIC SHOCK can kill. Diagram.
• Do not touch electrically live 5. Using a 7/16” wrench, label and remove leads
parts or electrodes with your BL1, BL2, BL3, BL4, BL5 and BL6 from the
skin or wet clothing. Chopper Board. Save the bolts and lock wash-
• Insulate yourself from the work and ground. ers 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
1. Remove the input voltage from the Power Figure F.40. See Wiring Diagram.
Wave® S500 machine.

POWER WAVE® S500

CHOPPER BOARD

FIGURE F.40 – CHOPPER BOARD LEAD LOCATIONS
R75 R3 R47
R74
C16
C15
X15
BL6
BL6
C24
D15
D115
DZ18
R76
OCI5
D13
FTP4
R77
R44
R2
R43
C17
R29
FTP-5V
J104
C26
BL5
BL5
L9
D116
FTP5
FTP15V
G6870-1
L1
R79 R78
FTP6
R1
R34
X16
C25
BL4
FTP1
J103
BL4
D117
C27
R45
R46
D111
DZ16
FTP2
R69
DZ17
R6
R66
R67
D112 R68
C58
D118
D119
BL3
J102
BL3
C57
X17
FTP3
C59
C65
MULTIPHASE CHOPPER
R65
C60
R70
FTP+3.3V
C64
R71 C74
R5
X19
D120
FTP_GND
BL2 BL2 C63
J101
D113
J41
J41
R73 R72
R4
LEAD 410
BL1
BL1
D114
LED1
LEAD 410
R9
J42
J42
R8
R7
B2
B1
B2 3/8 INCH B1
MOUNTING NUTS
(4 PLACES TOP
AND BOTTOM)
7. Using a 7/16” wrench, label and remove leads 9. Using a 3/8” nutdriver, remove the four nuts
B2 and 207 from terminal B2. Save the bolts securing the Chopper Board Assembly to the
and lock washers for reassembly. See Figure mounting posts. See Figure F.40.
F.40. See Wiring Diagram.
10. Carefully remove the Chopper Board Assembly
8. Label and disconnect the two thermostat leads (with heat sink) from the machine by clearing
409 and 410. These leads can be disconnect- all leads and lifting the lower portion up and out
ed at the two in-line push-on connectors. See first.
Figure F.40. See Wiring Diagram.
POWER WAVE® S500

CHOPPER BOARD
1. Position the new Chopper Board and heat sink 6. Connect leads B2 and 207 to terminal B2.
assembly onto the four mounting posts. Torque the bolts to between 50 to 60 inch
pounds. See the Wiring Diagram.
NOTE: The bottom of the Chopper Board
Assembly will have to be positioned into 7. Connect the six output choke leads previously
place first. removed from terminals BL1, BL2, BL3, BL4,
BL5 and BL6. Torque the bolts to between 50
2. Using the four nuts previously removed, secure
to 60 inch pounds. See the Wiring Diagram.
the new Chopper Board onto the mounting
posts. 8. Perform the Case Cover Replacement
Procedure.
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.
POWER WAVE® S500

RETEST AFTER REPAIR PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will aid the technician in testing the Power Wave® S500 output after the
repair or replacement of a part or PC board.
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
POWER WAVE® S500

RETEST AFTER REPAIR PROCEDURE (continued)

PROCEDURE
3. Turn the Power Switch OFF and connect a resis-
WARNING tive load across the Output Studs and a com-
puter to the Ethernet. Perform the Current and
ELECTRIC SHOCK can kill. Voltage Calibration Procedure to be sure that
the machine will produce proper weld output.
parts or electrodes with your
-------------------------------------------------------------------
1. Be certain that the machine is properly con-

nected 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.
POWER WAVE® S500

Return to Master TOC 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 ELECTRICAL DIAGRAMS G-2
WIRING DIAGRAM - (G7188)
POWER WAVE S500

TB
GENERAL INFORMATION
U CAVITY NUMBERING SEQUENCE
GND5
L3 L3
3 GND4
ELECTRICAL SYMBOLS PER E1537.

33A
32A
(VIEWED FROM COMPONENT SIDE OF P.C. BOARD)

4 417
1 415
2 416
5 418
33
32
TO V LEAD COLOR CODING

1
SUPPLY L2
2
3
4
6
5
6
7
8
L2 B - BLACK J10A1,
J10B1,
1
J2, J5, J11,
J31, J46,
1 2
J9, J13, J16,
1 3
R - RED J26, J27, J62,

J63
J62
J811, 2 J51, J111, 3 4 J112, J83, J1 4 6

W B5 317 N- BROWN
xxxxxxx
414 7 J2 J82, J81

L1 L1 413 2 J61
115 VAC
INVERTER PCB B6 318 V - VIOLET J8, J24, J28, 1 4
J3, J4,
1 5
412 6 J29, J43, J47,
G - GREEN
xxxxxxx
(ASSEMBLY G6571) J45, J61

411 1 OPTIONAL J63, J84
5 8 J86 6 10
DEVICENET N.A. PIN NEAREST THE FLAT EDGE OF LED LENS (ANODE)
ALIGNS WITH WHITE LEAD OF LED SOCKET. 1 8
1 6
J6, J7,
J12, J23,
358
371
372
416
373
553
356
374
65A 1 J41, J85

343
347
345
341
348
344
357
349
352
354
342
346
54
53
J25, J42 16
892
893
891
894
9
2 6 12 J87
66 3 J46
33A 4
33
10
1
2
3
4
5
6
7
8
9
11
12
10
1
2
3
4
5
6
7
8
CB1
5
9
6
2
3
4
1
1
2
3
4
1
2
3
4
10A 1 51A
F A
32 2 E
J4
DC BUS 3 H A
J11
3
J13
J2
J12
32A 4 52 G B B
34 1 BOARD J47 J
1 D
A 2 4
5 51 M K E
DIGITAL CONTROL BOARD 2 L15732
6 L
2 3
1 5
C
3 7 F C 4
C
B D
J15 52A
E D
G6682 4 8 S18657 (INSERTION END)
S12
021
- 73 (S DE RING E
ND)
S12021-79 (INSERTION SIDE)
OL
5
GND5
J7
J8
J3 S1 S4 S5
J6
S2
J5
6 S3
J9
115V 7
RECEPTACLE 8
12
10
15
11
14
13
16
12
16
15
11
14
13
10
3
2
1
2
4
1
9
8
7
6
5
4
3
8
1
3
3
8
7
6
6
5
4
2
5
1
4
2
3
(Neutral Bonded)
1
6
5
9 INPUT
10
SWITCH
ETHERNET
409
410
379
370
402
554
403
206
213
350
418
415
378
355
375
202
417
214
212
211
377
376
CONNECTOR
67
21
67E 67E 1 4 T1
4A
RJ 45 L1
ETHERNET S2
TYPE CABLE 67C 67D 2 VOLTAGE
21 3
SENSE 5 5A
L2 T2
RECEPTACLE
CB2 65A 4
10A 65 R/Y J56
6 6A
L3 T3
901A 901C / 901
1 353B
409
410
FAN / 206A
3 351B J53 901C THERMAL LED
2 359B 4 353 B1
B 200
314A
316A
331A
351
333A
328A
335A
336A
307A
315A
313A
326A
338A
337A
332A
308A
334A
8 901A
368
361
OHM B
N/U 2 359 CHOPPERCONTROL / 377 4
100 W
1 353A BOARD G6786 901 OPTIONAL 378 3 W
R/Y J55 5 351A KIT 376 2
16
14
15
13
10
12
11
8 348
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
1 353C 6 359A HEAT 207 K3001 USER 375 1

7 347 W B
FAN SINK INTERFACE PCB
3 351C 6 346 J51
CURRENT (ASSEMBLY G6554)
2 359C 351A 10 5 345
J41
TRANSDUCERS J31 CONTROL BD STATUS

J32
J33
B 66 9 4 344 RED/GREEN LED

N/U 351 8 3 343
2 342 214 4
3
4
1
2
359A 7 B2
359 6 1 341 211 3 S1
LEM
B2
B1
B3
J37
353A 5 B13 213 2 REMOTE
553A
65 4
B2
212 1 + AMPTROLS
ARC LINK
51D
53D
353
54D
52D
3
53C
51C
67D
54C
52C
218 4
B16
INPUT CONNECTOR
B11
GAS 553 350 2 CHOKES 215 3

SOLENOID LEM 53F A
(OPTIONAL) 554 355 1 L16139 1 216 217 2
+
315B
313B
336B
337B
331B
328B
4
333B
335B
314B
216
2
332B
316B
4
3
1
1
2
3
5
6
2 217
J42
554A 54F B
3 215
B12
J114
B5
4 218 J115 75 C
OUTPUT 316A 16 1 77A 1 77
10
13
14
15
11
16
12
76
1
D
2
4
5
3
9
7
8
B8 CHOKE 15 2 200A 2 200

L13270-4 REMOTE CONTROL PCB 3 4A 3 4
B7 314A 14 (ASSEMBLY G6948) 77 E
A 4 76A 4 76
J23B
BL1 13
S3 ARCLINK B20 336A 12 5 75A 5 75 200 F
B2 B56 POWER BOARD A2 J111
RECEPTACLE B6 BL2 337A 11 6 2A 6 2
G7150 2 G
331A 10 7 51K 7 51F
B23 B18 A3 6 361
BL3 328A 9 8 52K 8 52F 4 H
53A J23A 5 J112 9 53K 9 53F
ARCLINK - A B28 A4 315A 8
53B 51A 1 51A BL4 4 366 10 54K 10 54F 51F
B17 7 J26 J
54A 52A 2 52A A5 313A 6 3 J111
ARCLINK + BL5 L2
1
3
8
7
6
2
B
5
54B 67A 3 67 2 52F K
5
B10
54A 4 54A A6 1
B4
ELECTRODE 67A BL6 332A 4
371
379
374
L6
372
373
370
SENSE
C 53A 5 53A CHOKES 5.0 MF L
67B
CAP. 333A 3 PFC CONTROL BOARD
51B 6 51C T12218-37 CHOPPER BOARD 335A 12 362 L1
52A
L5 2 M
+40VDC D
52B
52B 7 52C G7245 G6860 11 326A
67B 8 67C B4 1
318 8 10
B15
51A 54B 9 54C B5

0 VDC E .01 MF 9 368
B9
51B 7 CASE BACK 402 6

L4 53B 10 53C 8 901A / 901
6 5
.01 MF PRESENT ON MACHINES J22 7 206
.0047uF J55 317 5 BUILT AFTER 4/19/2013 4 J25
L3 J36 B29 6 367 L5 +
B44
B55
4 B3 403 3
356 2 5 326B
3 4
B4 362 358 1 901B
2 10 3
1 B5 4A 9 2 208
J24
J21
A
J1 8 1 369
250 OHM 25 W
4
B B2 5A 7
J35
J34
366 3
DIFF_1 HIGH C 6 J20 100
M20305-1
G G 1 357 54 2 OHM
250 OHM 25 W
B1 6A 5 367
4
3
2
1
8
7
6
5
4
3
2
1
DIFF_1 LOW D B/G B/G 2 354 4 53 1 100 W

DIFF_2 HIGH E R R 3 352 3 369
B/R 4 349 INPUT BOARD
11
12
2
10
13
15
14
338A
334B
334A
16
307A
307B
308A
308B
209
338B
DIFF_2 LOW F B/R

6
6
5
4
3
2
1
9
8
7
5
4
3
2
1
54A
53A
J50 M22489-2 1 903B

52
51
S5 L7
307B
331B
337B
308B
335B
326B
333B
315B
332B
336B
334B
328B
338B
314B
313B
316B
SYNC/TANDEM
CONNECTOR - WORK
202
L6
1 GROUND BOND CIRCUIT
G
+24 VDC INPUT 2 894 S4 BASE TO EARTH GROUND PER THE
+24 VDC COMMON 3 893 DEVICENET GND1 VERTICAL PANEL
NATIONAL ELECTRIC CODE
GND2 CASEBACK
DNET CAN_H 4 892 CONNECTOR
GND3 CASEFRONT
DNET CAN_L 5 891 (OPTIONAL)
G7188 C
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

SCHEMATIC - (G7189 PG 1)
G7189 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED INPUT P.C. BOARD AND ARC LINK RECEPTACLE GRAPHICS.
MANUFACTURER: No
STUD+
USED FOR PRODUCTION MONITORING, STUD -
DOWNLOADING SOFTWARE, OR
LEM COMMON
UPLOADING MACHINE INFORMATION LEM FEEDBACK
BLK/RED
ETHERNET F -15VDC LEM SUPPLY
+15VDC LEM SUPPLY
4J50
2J50
3J50
1J50
CONNECTOR P50 RED E 21

RJ 45 67 67 67E
BLK/GRN D
TYPE
67E 21
READY H
READY L
KILL H
GRN
KILL L
C
ETHERNET
LOCATED
OUTPUT ON
SYNC-TANDEM LOCATED ON
CABLE
FAN ON
LEFT
4
CONNECTOR CASE FRONT
S4
+15V
REAR PANEL
COM
LOCATED ON S5 LOCATED ON DEVICENET
LOWER RIGHT
LEFT CASE
357
S2
352
354
349
206
202
214
211
213
212
CASE BACK, RIGHT CONNECTOR

379
372
374
370
373
371
67
21
417
418
415
416
BACK BOTTOM (OPTIONAL) VOLTAGESENSE
24 VDC
5J13 894 894 2 +24 VDC RECEPTACLE
10J7
11J12
9J7
8J4
7J8
J15
1J9
3J9
6J8
1J8
3J8
2J8
11J6
4J9
6J12
4J12
6J9
5J12
3J4
5J6
9J4
4J4
5J4
COMMON
2J13 893 893 3 +24 GND
AUTOREMOTE
DEVICENET CAN H
1J13 892 892 4 CAN_H SENSEUSE
VOLTAGE 891
DEVICENET CAN L P.81, P.82
TYPICAL FEEDBACK 4J13 891 5 CAN _L
FEEDBACK 4 VDC = 500 A
DIGITAL CONTROL
P.C. BOARD FOLDS BACK TO
10J4 553 553 553A U.I. KIT
Schematic: G4799 375 A WITH A 12J6 554 20 OHM K3001
SHORT CIRCUIT 12V PULL USER INTERFACE PCB
Assembly: G6682
(OPTIONAL)
SEE PAGE 2 FOR

BOARD LED HELP

6V HOLD Schematic: G6735
LOCATED ON UNDERSIDE 3J7 Assembly: G6554
OF ROOF PANEL, REAR 4J7 554 554A
8J7 GAS SOLENOID B1
4J115
2J115
3RD IN POWER UP SEQUENCE
3J115
1J115
7J7 LOCATED ON
250VAC
CASE BACK .0047uF
LOWER LEFT
53D
51D
52D
54D
1J12
12J12
7J12
3J12
9J12
2J12
10J12
8J12
1J11
13J6
10J6
11J7
2J11
1J4
2J4
3J5
2J5
6J7
S1 REMOTE
ARCLINK +
AMPTROLS
ARCLINK -
R OR Y FAN SPEED VARIES BASED ON
J56
348
341
342
343
344
345
346
347
TEMPERATURES OF BUCK/BOOST
+40VDC
376 375
409
410
377 378
358
402
356
403
ARCLINK
0 VDC
53
355
350
54
MODULES. 5V PWM CONTROL SIGNAL.

1 353B ALL REAR INTAKE SIDE EXHAUST.
4J51
2J51
1J51
3J51
FAN J51 RECEPTACLE
DATA OUTPUT B
CLOCK INPUT A
DATA INPUT A
CLOCK INPUT B
DATA OUTPUT A
DATA INPUT B
3 351B J53
+5V ISOLATED
+5V ISOLATED
FAN POS.
FAN CONTROL NEGATIVE
FAN CONTROL POSITIVE
4 353
COMMON
2 359B
SUPPLY
FAN NEG.
53D
51D
52D
54D
SECONDARY COMMON
B 8 351 53F A ARCLINK -

FAN SPEED CONTROL
FAULT SIGNAL +
N OR U 2 359
FAN POS.
B
LOCATED ON
B
1 353A
FAN NEG. CASE FRONT 54F B ARCLINK +
MACHINE
1J115
CAN H
3J115
CAN L
2J115
374 3J112
4J115
W
W
VDC-
5
+40V
R OR Y J55 351A
THERMOSTAT MIDDLE
6 359A 373 6J112 75 C 75
LOCATED ON 1 353C
FRONT OF FAN FAN SPEED CONTROL THERMAL STATUS 372 4J112
CHOPPER 3 351C 5V LED RED/GREEN 76 D 76
HEATSINK 2 359C 48 VDC FAN LED 371 8J112
359A
353A
B
351A
ARCLINK -
359
351
353
9J111 53F 77 E 77
N OR U 370 5J112
54F ARCLINK +
341
342
343
344
345
346
347
348
LOCATED 379 7J112

10J111 200 F ALPS
ON CASE LOCATED ON 0 VDC
51F
355
350
7J111
65
66
!!! HIGH VOLTAGE !!!

358
356
402
403
BACK TOP LOWER FRONT 2 G TRIGGER

FLOATING VOLTAGE REMOTE CONTROL PCB 52F +40VDC
48VDC CB2 RIGHT SIDE Schematic: G6947
8J111
POTENTIAL TO GROUND 10A
Assembly: G6948 ALPS
2J111 200 4 H TRIGGER
J46-1
4J37
65A
1J37
2J37
9J37
10J37
8J37
3J37
5J37
6J37
7J37
1J22
2J22
6J22
3J22
75
1J41
2J41
3J41
4J41
5J41
6J41
7J41
8J41
16J23A 316A
MAIN BUCK DRIVE A+
316A 6J32 J46-2 DC BUS 53C 1J114 LOCATED ON 5J111 75
51F J 0 VDC
MAIN BUCK DRIVE A- BOARD UNDERSIDE OF ROOF 76
8J23A 315A 315A 3J32 52 54C 3J114 4J111 76
ARCLINK 66 J46-3 Schematic: M19330 PANEL, FRONT
52F K +40VDC
53A 1J21 14J23A 314A
AUX BUCK DRIVE A+
314A 1J32 CHOPPER CONTROL BOARD LOCATED ON J46-4 Assembly: L11832 67D 5J114 1J111 77 77
L1
(SCHEMATIC G6785) FRONT RIGHT 51 TRIGGER L NOT USED
54A 2J21 AUX BUCK DRIVE A- +40VDC 4J47 6J111 2
6J23A 313A 313A 4J32 52C 6J114 L2
36 PIN IN LINE CONNECTOR 200 OHM 100 W
51 3J21 LED5 TRIGGER
LED1 COMMON 5J47 51C 4J114 3J111 4 M NOT USED
40VDC MAIN BOOST DRIVE A+ LED4
12J23A 336A 336A 15J33 207 206A
52 4J21 6-PHASE CHOPPER LOCATED ON
MAIN BOOST DRIVE A- +40VDC 8J47
4J23A 332A 332A 7J33 CASE FRONT
4J42 218
LED2
AUX BOOST DRIVE A+ TYPICAL LEM COMMON 52A

11J23A 337A 337A 5J33 COMMON 1J47
LED5 LOCATED ON 3J42 215
FEEDBACK LEM FEEDBACK 67E
AUX BOOST DRIVE A- RIGHT PANEL
PFC CONTROL
3J23A 333A 333A 12J33
REAR BOTTOM
4 VDC = 500 A 2J42 217
-15VDC LEM SUPPLY (See page 2
51A S3 ARCLINK LOCATED ON
P.C. BOARD 7J24 308A
FULL BRIDGE A+ 308A 8J33
FOLDS BACK 1J42 216 for LED RECEPTACLE CASE BACK, RIGHT
FULL BRIDGE A- +15VDC LEM SUPPLY information) 53C
Schematic: G6859 3J24 307A 307A 16J33 LED3 Schematic: G6869 TO 375 A WITH 10J55 10P55 53B
Assembly: G6860 Assembly: G7245 A SHORT CIRCUIT 53 5J55 5P55
L3 53A
A ARCLINK -
1J24 CT A* 334A 11J33
334A
LOCATED ON BACK POWER CONVERSION BL1
MULTI-PHASE
OUTPUT CHOKE
54C 9J55 9P55
L4
54B
B ARCLINK +
CT A LED1 54 4J55 4P55 54A
OF CASE FRONT 5J24 338A 338A 4J33 ASSEMBLY LED1 BL2 67C 8J55 8P55 67B ELECTRODE LEFT FRONT LOW
10J23A 331A
+15V A 331A 6J33 P.C. BOARD LED2
67 3J55 3P55 67A
C
SENSE
53 2J20 -15V A Schematic: G6845 BL3 52B STUD
2J23A 335A 335A 14J33 LED3 52C 7J55 7P55
Assembly: G7150 L5 D +40VDC TERMINALS
5J62 418 OUTPUT ON
54 1J20 BL4 52 2J55 2P55 52A

9J23A 328A
LEM A 328A 13J33 LED4 USED ON
LOCATED
FAN ON
51C 6J55 6P55 51B

BL5 L6 E 0 VDC K2904-1.
LEFT REAR
4J62 417 COM
+15V
11J25 THERMAL FAULT A 326A 3J33 LED5 51 1J55 1P55 51A

326A TWECO USED
REGULATES BL6 ON K2904-2
3J62 GND4
LED6 .0047uF
PRIMARY J55 P55
1J62 415
2J62 416
PRIMARY CAPACITOR VOLTAGE RIGHT FRONT LOW

VOLTAGE 9J25 368 368 1J33 LEFT
COMMON B2 B1
AND CONTROLS 6J26 361 361 10J33
EACH PHASE CONNECTED
CENTER 3J63 32
DEVICE TO SECONDARY COMMON 7J63 32A
SWITCHING 1J63 33 CB1 202 206
LED2 B56 B2 115 VAC CURRENT
9J23B 316B
MAIN BUCK DRIVE B+
316B 1J35 5J63 33A 10A
WELD CURRENT
INVERTER PCB 30 AMP PEAK SURGE (NOT WELDING) FEEDBACK FOR
901C/901 8J63 GND5 34
FEEDBACK
BUS 40 AMP PEAK SURGE (WELDING) CHOPPER BD
215
MAIN BUCK DRIVE B-
216
217
218
OPTIONAL
214
212
213
211
1J23B 315B 315B 4J35 901C/901A 901/901A
LED1
(ASSEMBLY G6571) RIGHT THERMOSTAT TURNS FANS MOUNTED MOUNTED ON
AUX BUCK DRIVE B+ BAR ON, LEFT THERMOSTAT CUTS OFF
xxxxxxx
11J23B 314B 314B 6J35 200 VAC PRESENT ON MACHINES 1J61 411 UNDERNEATH FRONT OF
2
3
1
4
115V IF FANS ARE STALLED
2
3
1
4
6J61 412 OUTPUT CHOKE OUTPUT CHOKE
3J23B 313B AUX BUCK DRIVE B-
313B 3J35
50 KHZ BUILT AFTER 4/19/2013
2J61 413
_
5J36 317 317 B5 115V
xxxxxxx
LED3 7J61 414 RECEPTACLE

8J36 318 318 B6
(Neutral Bonded) LEM LEM
MAIN BOOST DRIVE B+ .01 MF LOCATED ON
13J23B 336B 336B 11J34 B28 CASE LOCATED ON
RIGHT SIDE PANEL REAR PANEL +
5J23B MAIN BOOST DRIVE B- B18 .01 MF BACK
332B 332B 12J34
FRONT TOP RIGHT SIDE
B17 209
14J23B AUX BOOST DRIVE B+ 337B 9J34
200-600
337B
LED1 B29 VDC RMS 100 OHM 903B 901B
6J23B 333B AUX BOOST DRIVE B- 333B 1J34 DROP RED WIRE 100 W
TERMINAL BLOCK
B3 L4A FOR 1 PHASE
6J24 FULL BRIDGE B+ SWITCHBOARD P.C. BOARD LED LEGEND B4 B5 L4
U R LOCATED ON 208
308B 308B 6J34
LED1: BTM BUCK IGBT DRIVE OUTPUT CHOKE
2J24 FULL BRIDGE B- 14J34 INPUT VOLTAGE RANGE
307B 307B LED2: BTM BOOST IGBT DRIVE B2 ASSEMBLY
LED3: TOP BUCK IGBT DRIVE
INPUT LED1 L5A L5
V W
200VAC - 575VAC THREE PHASE
CT B* 220VAC - 415VAC SINGLEPHASE
4J24 334B 334B 10J34
LED4: TOP BOOST IGBT DRIVE P.C. BOARD 50 TO 60 HZ 1k OHM 25 W
RECTIFIED AC + CT B LED5: +48V AUXILIARY B1 L6A L6
369 1J25 8J24 338B 338B 2J34 Schematic: M22488 B 1k OHM 25 W
W MOUNTED ON
Assembly: M22489-2 LOCATED ON

SOFT START RELAY +15V B FRONT RIGHT LINE

367 6J25 15J23B 331B 331B 13J34 VERTICAL DIVIDER CASE FRONT
B13 MIDDLE SWITCH
-15V B B7 LOCATED RIGHT SIDE LOWER REAR LEFT ABOVE
10J1
+15V
6J1
3J1
5J1
362 12J25 7J23B 335B 335B 4J34 Schematic: S26517

PANEL REAR TOP G OUTPUT STUDS
RECTIFIED AC POWER + LEM B Assembly: M20305
366 4J26 16J23B 328B 328B 5J34 B6 B8
THERMAL FAULT B
BASE
LED4 5J25 326B 326B 3J34
362
366
369
367
GND1 VERTICAL PANEL

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.
GND2 CASEBACK MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND SCALE: EQUIPMENT TYPE:
GND3 CASEFRONT ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
POWER WAVE S500 PAGE ___ 3
1 OF ___
INPUT BACK ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: sajones DOCUMENT DOCUMENT
CHOKES LEFT
ON ALL ANGLES IS ± .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: LLUO
IF PRINTED
@ A1 SIZE SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
MIDDLE WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING APPROVED: GWM
UNITS:
INCH
MATERIAL
DISPOSITION: UF APPROVAL
DATE:
4/19/2013
PROJECT
NUMBER: CRM46188-B
REFERENCE:
G6535-2
G7189 C
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
Power Wave® S500

MANUFACTURER: No
CONTROL 115VAC INVERTER

P.C. BOARD P.C. BOARD
THERMOSTATS PRIMARY LED'S ARC ARC
COOLER SHUTDOWN FAN CONTROL CURRENT VOLTAGE
ENABLE ERRORS SENSE SENSE
115 VAC OUT
Description of LED functions on Power Wave S500
J5 J6
For reference only
Description of LED functions LOGIC
COMMUNICATION
J3 J5 J6 J7 J8 J9 on Power Wave S500 For reference only WITH CONTROL BD G6571 115 VAC INVERTER P.C. BOARD
J3
SI SYNC LED # COLOR FUNCTION

TERMINATION
LED2
LED1
SI LINK 1 RED
ERROR CODE (LED WILL FLASH ERROR) SEE TABLE BELOW FOR
O
O
O TERMINATION G6682 CONTROL P.C. BOARD DETAILS
N
N N
2 GREEN RECEPTACLE OUTPUT IS ON (115 VAC)
DIFF I/O LED # COLOR FUNCTION
J62 J63
S3 S1
J12
SIGNALS 3 GREEN INPUT POWER PRESENT. POWER SUPPLY ON

1 GREEN STATUS "OK"
J12
LED5
LED6
LED3
LED4
CHOPPER
LED2
2 RED STATUS "ERROR" (CHECK CODE FOR SPECIFIC ERROR)
CONTROL LED 3 ERROR CODE
3 GREEN OUTPUT ENABLE
BT1
ERROR EXPLANATION
4 GREEN SINGLE PHASE FAULT
200 VAC 50 KHZ IN 1 GROUND FAULT
BT1 5 GREEN ELECTRODE SENSE
RJ45 (ETHERNET) LED 1 2 THERMAL FAULT
6 GREEN WORK SENSE J61

3 15V CONTROL UNDERVOLTAGE
J15 LED 8 LED 9 7 GREEN ETHERNET LINK/ACTIVITY STATUS

B5 B6 4 200V BUS UNDERVOLTAGE
LED 7 8 GREEN ETHERNET SPEED STATUS
5 OUTPUT OVER CURRENT
LED10
S2
DIGITAL CONTROL
G6682-1
9 GREEN INPUT SUPPLY 30 VDC TO 55 VDC

O
O
ARCLINK 6 OUTPUT OVER VOLTAGE
N
N
TERMINATION 10 GREEN DEVICENET EXTERNAL 24 VDC PRESENT
J13 J2 J4
J11
J11
J13 J2 J4
THERMAL
FAULTS
ARCLINK DEVICENET INPUT POWER

COOLER INTERFACE
PFC CONTROL
+40 VDC BUS
A-SIDE BUCK-BOOST
DRIVES LEM FEEDBACK P.C. BOARD B-SIDE BUCK-BOOST
DRIVES LEM FEEDBACK
P.C. BOARD J23A

C4
C6
J23B
R7
R8
D9 D11
R3
R4
D17
D8
C5
D22
D21
D5 D6 D7 D18 D19 D20

D2
D1
C7
T1 X7
Q10
X1 D12 Q1
D10
C8
C9
X2 X3 X5 X6
C2
C3
D23
D24
D3
D4
Q9
Q2
C20 LED 2
D14
D16
INDICATES OUTPUT
C12
C1 X4 C10
DZ1
DZ2
LED 5
DZ3
DZ4
DZ5
DZ6
DZ7
DZ8
C11
C24
C25
C23
C21
D13
D15
X8 X12
D25
L1
OCI1 OCI2 OCI3 OCI4

J24
D28 D29
D43
D44
X18 X19 X17 X16

FTP23
R257
D26 D27
R65
R1
C13 C14
DZ10
FTP20
C19
Q4
D45
D46
D47
D48
C35
Y2
D30
D31
D41
D42
D39
D40
X31 FULL BRIDGE DRIVES

C15
C17
FTP5
LED 3 X13 X14 1 LED2
CURRENT FEEDBACKS
FTP4
LED5
C27
C26
J2
LED 1
J47
FTP14
Y1
C22
C16
FTP13
J46 FTP15
1 J1 X20
X22
D52
D53
D54
D55
DZ9
X21
Q3 D49 FTP6
X24
J25
FTP10
FTP24
X26 OCI5
FTP22
FTP18
FTP12
R57
C39
C74
R56
J22
FTP11
LED1
DZ11
LED1
R86
R92
DZ17
FTP1
FTP2
X25
OUTPUT INPUT
DZ18
X27
RELAY DRIVE, BUS VOLTAGE
LED3
DZ12
C66
R110
R84
R91
D36 D33 D35 D38 D34 D37
FEEBACK, AC VOLTAGE FEEDBACK,

D64
40/36V OUTPUT AND DZ19

AND TEMPERATURE FEEDBACKS
D58
X9 D56 C30
D50
Q8
FAULT SIGNAL TO C29 C31
J21
DZ20 D57
DIGITAL CONTROL BD
D62
D59
D68
CAN AND
D65
D63
X29 X30 Q7
J26
40V INPUT
T2
D61
J20
D60
DZ22
C32
R2
D67 D66
C33
LED 4 C34
Q6
G6860-1 POWER IN
R210
R209
R212
LED4
D69
FTP3
ERROR CODE
Description of LED functions on Power Wave S500 ERROR EXPLANATION
L15732-1
For reference only 331 PEAK INPUT CURRENT LIMIT
334 START UP CURRENT CHECK FAILURE

G6860-1 PFC CONTROL P.C. BOARD
335 START UP VOLTAGE CHECK FAILURE
LED # COLOR FUNCTION

GREEN / STATUS LIGHT AND ERROR CODE (LED WILL FLASH ERROR) SEE 336 THERMAL FAULT (NO FIRST STAGE FAN)
1
RED TABLE FOR DETAILS
337 PRECHARGE TIMEOUT
2 RED FAULT SIDE B
338 INPUT POWER LIMIT
3 GREEN -15 VOLT PRESENT
341 INPUT VOLTAGE DROPOUT
4 GREEN +15 VOLT PRESENT PROPRIETARY & CONFIDENTIAL:THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OW NED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
346 TRANSFORMER PRIMARY OVERCURRENT TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
5 RED FAULT SIDE A MANUFACTURING TOLERANCE PER E2056
347 AVERAGE INPUT CURRENT LIMIT ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
POWER WAVE S500 3
2 OF ___
PAGE ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: sajones DOCUMENT DOCUMENT
349 BUS UNDERVOLTAGE ON ALL ANGLES IS ± .5 OF A DEGREE
IF PRINTED
WITH PUBLISHED STANDARDS.

UNITS:
INCH
MATERIAL
DATE:
4/19/2013
PROJECT
NUMBER: CRM46188-B
REFERENCE:
G6535-2
G7189 C
Power Wave® S500

MANUFACTURER: No
MULTIPHASE
INPUT BOARD LEDS 1-6 ON DAUGHTER BOARD CHOPPER
SHOW EACH PHASE IS ACTIVE
3 STAGE INVERTER
FROM CONTROL BOARD
PRIMARY HARNESS R75 R3
R74 R47
C16
C15
X15
R6 R3 R7
SWITCHBOARD
BL6
C24
D15
D115
J1
C1
DZ18
P.C. BOARD
C2
D7
R76
OCI5
D13
FTP4
R77
R44
R2
R43
C17
LED 1 R29
R5
FTP-5V
INDICATES INPUT
J104
C26
BL5
VOLTAGE IS PRESENT
TO MULTIPHASE CHOKE L9
D116
C3
FTP5
D2
CR1
D1
D3
FTP15V
G6870-1
L1
R4
R79 R78
LED1
FTP6
R1
R34
X16
C25
B3
A1
FTP1
J103
BL4
D117
R8
C27
R11
R45
R46
B4
RUBBER
D111
SLEEVES
DZ16
ON BASE OF LED 4 LED 3
FTP2
CAPACITORS
R69
D5
DZ17
R6
R66
R67
R68
B5
AC INPUT
D112
C58
D118
TO SWITCHBOARD
D119
J102
BL3
B2
C57
X17
R10
FTP3
C59
C65
J32 J33
MULTIPHASE CHOPPER
R65
C60
D6 R70
FTP+3.3V
CR2
C64
C74
LED 5
R71
B28 L3 B29 R5
R74
R75
M22489-2
X19
INPUT
D120
C35
FTP_GND
BL2
R70
D4
C63
J101
R66
R7
LED4
D113
R9
R71
LED3
J41
XXXX B13
R1
R2
FTP3
B1
LED5
C10
TO SECONDARY
B3
B1
R53
B2
C12
R73 R72
DZ25
DZ23
HARNESS
R36
R29
DZ22
C9
D14
R4
R30
D15 R34
C19 R35
R31
R50
R51
R49
BL1
DZ26
D114
DZ24 R1
R54 R27
B11 C11 R3
B16
LED1
T4 R2
DZ17
DZ3 TO TOP
R60
T3
R9
R61
D4
INPUT CHOKE
DZ11
DZ1
R67
R58
R45
40V AUX
R8
D5
D2
C38
DZ4
USE
J42
R8
R55
R7
TO LOWER
DZ9
R59
R47
DZ12
C15
R16
R15
DZ10
D3
B2
B1
R48
R18
R17
OCI1
LEM
C16
D1
R52 B12 B5
DZ2
R46
C14
R14
R13
X1
J37
R12
C13
R11
C21
C18 C40
TO B2 ON
D12
D13
CHOPPER BOARD B8
TO B56 ON POWER BOARD
C25
LED 1
T5
INPUT CAPACITOR
C17 ON WHEN
L2 15 VOLT PRESENT
HEATSINK THIS SIDE C33
TO POWER BOARD BUS BAR
SECONDARY POTENTIAL
AND POSITIVE STUD

B56
C23
B20
L4
B58
R81 B7 BOTH HEATSINKS

B6 X2
THIS SIDE FLOATED
D11
R80
R79
B57
D10
R78
B18 B17
B23
C24
C20
S500 POWER
LED2
FTP1
G6846-1
R28
DZ21
C36 C2 DZ19
R39
R6
R37
C22
DZ18
D16
R9
C1
R68
R32
R38
R4
B10 B4 LED 2
R63
D7
C4
R5
J36
R10
R69
DZ20
D17
R33
DZ15
R20
DZ5
R40
C39
C3
C7 R21
115V AUX R22
USE C8
TO BOTTOM
INPUT CHOKE
R62
R44
B9 D6
B15
R19
T2
R43
DZ6
DZ16
R65 DZ14
B44
R72
R73
B55
TO CHOPPER BOARD
Description of LED functions on Power Wave S500
LED1
D9 R42
R25
AND POSITIVE STUD
D8
R64
DZ13 T1 DZ8 R26
XXXX For reference only

C37
DZ7
C6
T6
C5
R24
R41 R23 G7150 SWITCHBOARD P.C. BOARD
L1
R77
R76
LED # COLOR FUNCTION

C34
1 GREEN BTM BUCK IGBT DRIVE FUNCTIONING WHEN ON
J35 J34 2 GREEN BTM BOOST IGBT DRIVE FUNCTIONING WHEN ON
3 GREEN TOP BUCK IGBT DRIVE FUNCTIONING WHEN ON

4 GREEN TOP BOOST IGBT DRIVE FUNCTIONING WHEN ON

5 GREEN 48 VDC AUXILIARY POWER FUNCTIONING WHEN ON
LED 1
MANUFACTURING TOLERANCE PER E2056
= MOLEX PIN 1 ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) NONE
3 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: sajones DOCUMENT DOCUMENT
IF PRINTED

UNITS:
INCH
MATERIAL
DATE:
4/19/2013
PROJECT
NUMBER: CRM46188-B
REFERENCE:
G6535-2
G7189 C
Power Wave® S500

CONTROL PC BOARD ASSEMBLY (G6682-1 PG 1)
G6682-1 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED ITEM 9 PART NUMBER

MANUFACTURER: Yes
N.E.9
ASSEMBLY NOTES
N.A.1 PLACE CONNECTOR KEYING PLUG, ITEM 7, OVER CONNECTOR PIN AT LOCATION SHOWN. PLUG
.74 SHOULD BE INSERTED BELOW CONNECTOR TOP SURFACE.
N.A.2 PROGRAM X18 WITH ITEM 8.
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.E.8 N.E.7 N.E.6 N.A.6 PLACE ITEM 12 OVER ITEM 11. PROTRUSION OF ITEM 12 MUST ALIGN WITH PROTRUSION OF ITEM 11.
7 N.A.1 9 N.E.5 8 N.E.5 7 N.A.1 N.E.5 BOTTOM OF ALL FOUR SIDES OF ITEM 12 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.
DZ1
DZ2
D1 D3 N.E.2 AFTER POTTING, THE TOPS OF THESE COMPONENTS MUST BE FREE OF MASKING AND POTTING
D47
D46
D45
D44
Q3 Q6 MATERIAL.
D7
D9
J5 J6 J7 J8 J9 N.E.3 PRIOR TO POTTING APPLY ITEM 5 TO SEAL THE BOTTOM OF THE CONNECTOR CAVITIES TO PREVENT
D19
DZ7
POTTING MATERIAL FROM GETTING ONTO THE PINS. (AFTER APPLYING GREASE, A NON-PINNNED
DZ6
MATING CONNECTOR MAY BE USED TO PUSH THE GREASE INTO THE BOTTOM
D22 OF THE CAVITIES.
D4 D6 3 N.E.4 SEAL BASE OF COMPONENT J15 ON ALL 4 SIDES WITH ITEM 14. RTV MUST FLOW COMPLETELY
DZ8
D8 X100 AROUND COMPONENT WITH NO GAPS. COMPLETELY COVER MOUNTING HOLES AND BLACK PLASTIC
LED1
LED2
X26 MOUNTS. ALLOW RTV TO CURE PRIOR TO POTTING.

D10
D11
Q1 D17
J3
D2 D5 X11 N.E.5 SEAL BASE OF X18, X19, X20, X32, X47, X48 AND X50 WITH ITEM 14 ON ALL 4 SIDES ON COMPONENT
DZ3
DZ4
X8
X94 X96 X95 X97

D16
SIDE OF BOARD. RTV MUST FLOW COMPLETELY AROUND COMPONENTS WITH NO GAPS. ALLOW RTV
DZ5
N.E.2, N.G.3 X5 X9 X10
L2
TO CURE PRIOR TO POTTING.
N.E.6 PLACE BARCODED ASSEMBLY NUMBER LABEL IN AREA SHOWN.
X79
X4 X99 X24 N.E.7 PLACE BARCODED SERIAL NUMBER ID LABEL IN AREA SHOWN.
C6
L1
Q24 X93 X98 C8 N.E.8 PLACE MAC ID NUMBER LABEL IN AREA SHOWN.
2 N.E.9 AFTER THE POTTING MATERIAL IS CURED, CHECK BOTTOM POTTING TRAY SURFACE FOR WARPAGE.
OCI2
X13
X15
THE SURFACE IS TO BE FLAT WITHIN .05 F.I.M.

X22
X40
Q14 N.E.10 REMOVE PREHEATED ASSEMBLY FROM OVEN AND IMMEDIATELY DISPENSE POTTING MATERIAL
Q25 Q11 Q31 X38 BETWEEN TRAY / BOARD ALLOWING THE MATERIAL TO FLOW UP AROUND ALL FOUR SIDES PRIOR TO
X75 X21
X18 X19 DISPENSING OVER THE TOP. POTTING MATERIAL SHOULD BE TO A MINIMUM DEPTH SUCH THAT ALL
X39
X20 SURFACE MOUNT AND THROUGH-HOLE IC CHIPS, BODIES AND LEADS ARE COVERED. BRUSH COAT
FTP8
FTP6
O O
N N BODIES AND LEADS OF L5, L10, L11, L12 AND L14.
X14
S3 S1
OCI1
N.E.11 DISPENSE RTV ON SECONDARY SIDE OF BOARD TO COMPLETELY COVER MOUNTING HOLES AND
FTP7
BLACK PLASTIC MOUNTS FOR BT1 AND J15. ALLOW RTV TO CURE PRIOR TO POTTING.
Q10 X41 X25 X36 X85 X12 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.
J12
L6
LED3
LED6
C110
X33 Q16 X34 GENERAL NOTES

X83 X82 X29 X28 N.G.1 CAUTION: THIS ASSEMBLY IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY.
LED4
LED5
L8
N.G.2 THERE ARE COMPONENTS ON BOTTOM SIDE OF P.C. BOARD.
C325
N.G.3 S1, S2, S3 SWITCHES MUST BE IN THE “ON” POSITION AFTER POTTING,
FTP4
FTP5
L14
Y1 X92 N.G.4 KEEP AREA AROUND CONNECTOR LOCKING TABS FREE OF POTTING MATERIAL A MINIMUM OF 0.15”
N.A.6 IN ALL DIRECTIONS.
X32
X81 N.G.5 RTV ON BOTTOM SIDE OF BOARD COULD TAKE 4 HOURS MINIMUM AT ROOM TEMPERATURE TO
L5
L13
L4
N.A.5 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
FTP2
R510 X35 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
BT1 14) RTV.
Y2 FTP1
R6
X50
X47
11 12
D54
R12
X46 R21 X51
X48
FTP3
D55
X52
N.E.4
L7
R15
X49
LED9
10
C9 C10 CT1
X78
C255
LED8
T1
Y3 X63
X62 Q20 C11 C12
J15
X53 R24
N.A.7
X61
L9
LED7
D30
REVISION CONTROL
X77
Q18
X65
N.E.2, N.G.3 X1
L10
OCI7 OCI8 L11 L12 DIGITAL CONTROL G6682-1M0

X58
T2
G6682-1
DZ31 DZ32
OCI10 OCI9 C14
PART NO. IDENTIFICATION
X54
Q19
CODE
X60
O X59 C13
Q21
N
S2 OCI5 OCI6 D38 D39 D40 D41 TEST PER E4338-C
D37
C17
POT WITHE2527
C15 X64
D35 X68 Q22 Q23 SCHEMATICREFERENCE: G4799-4M0
C19 C22
BUYAS G6682-1M0 PERE3867
LED10
N.E.1
X67
3 D42 8 LAYERBOARDBLANKPANEL PERE3281-ROHS
DZ24
DZ23
D43
C18 C20
X70 SEEELECTRONIC FILE FORADDITIONAL INFORMATION.
J13 J2 J4 X72 X73 X74
J11
C287
C252
X57 C21
X69
X71
C292
OCI12
N.E.5
N.A.1 7 7 N.A.1 TOP VIEW 10 N.G.1

ALL COMPONENTS AND MATERIALS USED IN THIS

ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) 2:1
POWER SOURCES PAGE ___ 3
1 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: fivory DOCUMENT DOCUMENT
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: EF
IF PRINTED
@ A1 SIZE SUBJECT: DIGITAL CONTROL P.C. BD. ASSEMBLY NUMBER: REVISION:

DO NOT SCALE THIS DRAWING APPROVED: BS
UNITS:
INCH
MATERIAL
DATE:
8/24/2012
PROJECT
NUMBER: CRM44934
REFERENCE:
G4800-3
G6682-1 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 pro-
vided 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
Power Wave® S500

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OW NED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
DOCUMENT
REVISION:
F
2 OF ___
PAGE ___ 3
OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
G6682-1
DOCUMENT
DIGITAL CONTROL P.C. BD. ASSEMBLY NUMBER:
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 pro-
G4800-3
REFERENCE:
POWER SOURCES
CRM44934
PROJECT
NUMBER:
1
N.G.2
8/24/2012
APPROVAL
DATE:
EQUIPMENT TYPE:
UF
DISPOSITION:
SUBJECT:
C81 R169 C79 C85 C89 C328 C329
MATERIAL
R176
R189 R180
C84
R192 R170 R158
R171
R38
R191 R212
IF PRINTED
@ A1 SIZE
C282
INCH
C25 R173
R165
2:1
R177 R426
SCALE:
UNITS:
R164 C283
R39 R41 R181 R159 R155 C244 R427
R42 C4 C284
C133 R428 R429
R44 R45 R46 C80 R162 R34
R36
R594
R431
R33
C327 C245 R430
PROPRIETARY & CONFIDENTIAL:TO

R35
UNLESS OTHERWISE SPECIFIED TOLERANCE: CONTROL: CLEVELAND

R167 R30
R31 C340
fiv ory
BS
EF
R32
R48 R147
D53
D48
R152 R432
C24 C285
R150 C23
C28 C316 C246
R160 C77
R204
APPROVED:
R433
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY:

C27
ENGINEER:
R587
R50 C132 C286
R291 R201
R156 R390 R434

R43 R49 R47
D52
R586
R294 C288
R53 R437
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)

C26 C29 C343 C344 C248 R435
DO NOT SCALE THIS DRAWING

D49

R319 R207 R436 C289
MATERIAL TOLERANCE (" t ") TO AGREE

R54 R52
R51

C33
R320
R289 R206 C247 R438
C32 C34

R595
R290
C30 C249
C138 C338
C35 C135
C36 R55 C134
R293
C290
C31
D23
R299 R391
R57 R168
R58 C37
R302 R298
C38
R307
R303
R300 R175 R178 R392 C291
R305
R56 R59 R310 R172
R309 C83
R313 C7
C82 C250
R63 R60 R312
R585 R174
R62
R196
R200
R179 R584 R182
R61 C88
D50
R203
R183
R209 C131
R393
R64
C90 R208 R579
R439
R65
C130 C129
R394
R580
C346 R440
R578 R581 R210
R288
C345 C293
R577 R211
R582
R500 R583 R213 R442
C347
R214 C91 R441
C92
R496 C141 C200
C93 R321
C39 C40
R4
R71
C41 R522
R443
C142 C201
R521 D56 R446
C202 R3
C43 C44 R524 R444
R598
R525
C367
R73 R523
R601
C45
R499
C294 R445 R447
C143
C46 C251
R603 C94
C144
D57 R395
R75 C47 C95
R599
R322
C48 C96
R602 R78 C145 R397 R449
C97 R400
R600 C98 R323 C146 C203
R396 R450
R215
R401
R216
R324
R81 R218 R501
D58 R398
C361
C147 R402
R83 R87 C53 R219
R509
C295
C296
C99 R220 C148 C159 C163 R454
C100 C167 C217 R451
C366
R592 R86 C101
R221
C149
C166 R504 R453
R452
C51 C102 C162
C160
R223 R503 C215
C360 R222 C156 C297
R84 C50 R325
C165
R506 R508
ELECTRICAL DIAGRAMS
R333
R90 R326 C151
R455
R89 R367
C210
C365 R332 R456
R327
R88 C52
R368 C208
C204
R457
R505
R93
C157 C216 C209
R91 C211
R92
R328
R329 C153 C253
R96 DZ26
R458
C206 C150
R95 R94
C359 C218
R100 C161
BOTTOM VIEW
R370 C212
R97
R98 C103
C164
R403 R459 R460
R224 R369
C104
R85 C362 C105
R225 C106 C168 R502
R99 R404 R461 R462
R591 C169
R507
R103
C364
R557
R405 R463
C207
R102 R101 C219
C158 C256 C254 R465
C107 C108 R464
R566
R371 C155
C109 R227 C154 C258 R466
R564 R568
C363
R334 C205 R467
R468
R565 R567
R530
C257 C260
C213 R469
C170
C54 C56
R106 C152 R470
R230 R529
R471
R109 R108 R498 R472
R335 C172 R406 R407
R111 R112 R107 R231
C171 R473 R474
R110
R336 C174 C261 R408
C58
C16 C339
R338
R409 DZ27
R375 C259
C57
C173 R411
C60 C61
R448
R497 R233
R337
R340 R376 C262 DZ28
R232 C263 R410
R115 R116
C175 C300
C298
C299
C264
R613 C220
C265 R412
R117 R118 DZ29
R377
C301
R414 R413 C302
C62 C63
R343 C222
C221 C266 DZ30
C304
R475
C177 R380
C349 C267
C178
R513 R381
C226
C224
R382 C268
C303
R476
R415
R515
R385
R344
C179
R384 C223 C225 R2
R416 R477
R514 C42
R387
C348
R346 R345
C227 R1
C180
R379
C181 R388 R378 C309 C315
C182
C66
C183 C310
C184 C312
R120
R347
R386
C313
R121 R526 R241 R240 R348 R383 R485
C311
R234 R236 R235 R349
C67
C111
C314
C185 C228
C270
C187
C229
C120 C114
C189
C272
R252 C231 C233
C232
C190 C273
R243 R238 C234
R248 C235
C191 C274
C113 C236
R237 R239 C237
C193
C112 R389 C238
C69 DZ12 C186
R350
C239
R127
DZ10 C188
R124 C70
R129 DZ11 R352 C230
R125 R126 C198
R130 DZ9 R527 C269 R481
C72
Q29
R355
R260 C321
C322 R417
C197 R354 C271
C71 R128
R262 C195 R353 R517
R418 R421
R131 C307
R258 C196 R516 R520
Q28
C73 R420
R611
R519 C306
R132 C119 R608
R518 C305
DZ21 R419
R483
R134
R266
R133 R264 R480
CHANGE DETAIL: REVISED ITEM 9 PART NUMBER

C336
R574 R478
R263 R479
R136 R135 R137 R569 C240 C278
R570
R573 C241
C279
R138 R139 R140 C324 C337
C280

R609 C335 C242 R610
R141 R575 C281
R142 R143 C323 R606 C243 R607
R144 R576
R572
R145 C276
R571
C320
N.E.11
ENGINEERING CONTROLLED
MANUFACTURER: Yes
G6682-1
machine.
NOTE:
G-7
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
G6682-1 ENGINEERING CONTROLLED CHANGE DETAIL: REVISED ITEM 9 PART NUMBER

MANUFACTURER: Yes
J2, J5, J11 3 S24020-4 CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN R156, R291, R571, R572, R573, R574,
8 S25001-26R7SMT RESISTOR,SMD,26.7OHMS,1/4W,1206,1%,TR
J3 1 S18248-10 CONNECTOR,MOLEX,MINI,PCB,10-PIN R575, R576
ITEM USED WITH * QTY PART NUMBER DESCRIPTION J4 1 S24020-10 CONNECTOR,MOLEX,MINI,PCB,10-PIN,TIN R159, R160, R289, R300 4 S25000-3921SMT RESISTOR,SMD,METAL FILM,1/10W,3.92K,1%,S0805
1 1 G4800-M PC BOARD BLANK
N.E.3 J6, J7 2 S24020-16 CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN R164, R165, R171, R173, R176, R177,
8 S25007-1002SMT RESISTOR,SMD,PREC,MF,1/10W,10.0K,0.1%,S0805
2 1 M19436-14 POTTING TRAY J8 1 S24020-8 CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN R180, R181
3 2 S8025-80 SELF TAPPING SCREW J9, J13 2 S24020-6 CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN R168, R212, R443, R444 4 S25001-1501SMT RESISTOR,SMD,1.5K,1/4W,1206,1%,TR
4 10.2 oz E2527 EPOXY ENCAPSULATING RESIN J12 1 S24020-12 CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN R169, R170, R208, R345, R441, R570 6 S25012-2671SMT RESISTOR,SMD,METAL FILM,1/16W,2.67K,1%,S0603
5 0.16 oz E3539 ELECTRICAL INSULATING COMPOUND N.E.4 CONNECTOR,MODULAR,HIGH-SPEED,VERTICAL,INTERNAL- R179, R182 2 S25001-2000SMT RESISTOR,SMD,200OHMS,1/4W,1206,1%,TR
J15 1 S25104-1
6 0.18 oz E2861 RTV COMPOUND SHIELD,8/8 R189 1 S25012-1502SMT RESISTOR,SMD,METAL FILM,1/16W,15.0K,1%,S0603
7 4 S24671 PLUG, KEYING PLUG L1, L2, L4, L6, L7, L8, L9, L13 8 S25083-6SMT CHOKE,SMD,RF,FERRITE_BEAD,600 OHMS R215 1 S25012-2000SMT RESISTOR,SMD,METAL FILM,1/16W,200OHMS,1%,S0603
8 (X18)* 1 Y00556-2 FIRMWARE FOR CPLD L5, L10 2 S25083-8SMT CHOKE,SMD,POWER,27UH,10%,1.75A R240, R241, R243, R252, R411, R412,
9 (X32)* 1 S26773-12 SOFTWARE FOR FLASH L11, L12 2 S25083-7SMT CHOKE,SMD,POWER,18UH,20%,3.9A,LS127-180-RM 7 S25000-2000SMT RESISTOR,SMD,METAL FILM,1/10W,200OHMS,1%,S0805
R419
10 (D30, Q21)* 2 S20590-6 HEAT SINK,CLIP-ON,STAND-UP,FOR TO-220 L14 1 S25083-4SMT CHOKE,SMD,POWER,10UH,10%,1.02A, R258, R262, R263, R264, R478, R480 6 S25001-1500SMT RESISTOR,SMD,150OHMS,1/4W,1206,1%,TR
11 (BT1)* 1 S25125-2 BATTERY HOLDER,VERTICAL 20mm COINCELL,SLIMLINE LED1, LED3, LED4, LED5, LED6,
9 S25080-2SMT LED,SMD,GREEN,CLEAR,S1206 R298, R449 2 S25012-5111SMT RESISTOR,SMD,METAL FILM,1/16W,5.11K,1%,S0603
12 (BT1)* 1 S27541 BATTERY COVER LED7, LED8, LED9, LED10 R310 1 S25000-6811SMT RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
13 (X49)* 1 Y01310 FIRMWARE FOR CLOCK GENERATOR
LED2 1 S25080-1SMT LED,SMD,RED,CLEAR,S1206 R324 1 S25000-1501SMT RESISTOR,SMD,METAL FILM,1/10W,1.50K,1%,S0805
14 .25 oz E2519-1 RTV COMPOUND
OCI1, OCI2 2 S15000-36SMT OPTOCOUPLER,SMD,TTL-OUT,DUAL,HIGH-SPEED R325, R326, R327, R328, R481 5 S25000-4750SMT RESISTOR,SMD,METAL FILM,1/10W,475OHMS,1%,S0805
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW OCI5 1 S15000-28SMT OPTOCOUPLER,SMD,TTL-OUT,HI-SPD,HI-CMR R334, R390, R392, R393, R394, R405 6 S25003-15R0SMT RESISTOR,SMD,1W,15.0OHMS,1%
OCI6, OCI7, OCI8 3 S15000-35SMT OPTOCOUPLER,SMD,3.3V,HIGH-SPEED,HCPL060L,SO8 R337, R408 2 S25000-5621SMT RESISTOR,SMD,METAL FILM,1/10W,5.62K,1%,S0805
REFERENCES QTY PART NUMBER DESCRIPTION OCI9, OCI10 2 S15000-32SMT OPTOCOUPLER,SMD,CMOS,HIGH SPEED,HIGH CMR,SO-8(SS) R340 1 S25000-1372SMT RESISTOR,SMD,METAL FILM,1/10W,13.7K,1%,S0805
BT1 1 S25125-3 BATTERY,LITHIUM,PLOYCMF,20MM COIN,3V,190MAH OCI12 1 S15000-34SMT IC,SMD,OPTOCOUPLER,HMA124 R344 1 S25000-9091SMT RESISTOR,SMD,METAL FILM,1/10W,9.09K,1%,S0805
C4, C7, C70, C83, C175, C261 6 S25020-2SMT CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
Q1, Q3, Q6, Q14, Q31 5 S25051-7SMT TRANSISTOR,SMD,NMF,SO-8,3A,50V R346, R347, R455, R456 4 S25000-10R0SMT RESISTOR,SMD,METAL FILM,1/10W,10.0OHMS,1%,S0805
C6, C8 2 S25030-2SMT CAPACITOR,SMD,METAL FILM,0.1MF,50V,5%,PPS
Q10, Q11, Q18, Q19, Q24, Q25, Q28, R381, R384 2 S25000-47R5SMT RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
C9, C10, C15, C18, C19, C20, C21 7 S13490-197 CAPACITOR,ALEL,82,35V,20%,LOW-ESR 8 S25050-2SMT TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
C11, C12 2 S13490-184 CAPACITOR,ALEL,330,100V,20%
Q29 R391, R465, R468, R471, R474 5 S25001-2671SMT RESISTOR,SMD,2.67K,1/4W,1206,1%,TR
C13, C22 2 S13490-198 CAPACITOR,ALEL,1000,35V,20%,LOW-ESR Q16, Q20, Q22, Q23 4 S25051-15SMT TRANSISTOR,SMD,NMF,7.3A,30V,SO-8 R395, R397, R401, R402 4 S25001-4752SMT RESISTOR,SMD,47.5K,1/4W,1206,1%,TR
C14, C17 2 S20500-16 CAPACITOR,PPMF,0.0033,630V,5%,BOX Q21 1 S18395-55 HEAT SINK ASSEMBLY,T12704-110 & S20590-6 (SS) R396, R398 2 S25001-3321SMT RESISTOR,SMD,3.32K,1/4W,1206,1%,TR
C16, C54, C58, C60, C62, C63, C66, R1, R206, R207, R448 4 S25012-4751SMT RESISTOR,SMD,METAL FILM,1/16W,4.75K,1%,S0603 R400 1 S25000-3321SMT RESISTOR,SMD,METAL FILM,1/10W,3.32K,1%,S0805
9 S25020-4SMT CAPACITOR,SMD,CERAMIC,820pF,50V,5%,COG,S0805
C67, C69 R2, R428, R564, R565, R566, R567, R403, R404, R459, R461 4 S25003-0R10SMT RESISTOR,SMD,1W,0.1OHMS,1%
C23, C24, C27, C28, C33, C34, C35, R568, R598, R599, R600, R601, R602, 13 S25012-1301SMT RESISTOR,SMD,METAL FILM,1/16W,1.30K,1%,S0603 R409 1 S25000-2802SMT RESISTOR,SMD,METAL FILM,1/10W,28.0K,1%,S0805
C36, C37, C38, C79, C81, C82, C84, R603 R415 1 S25000-3570SMT RESISTOR,SMD,METAL FILM,1/10W,357OHMS,1%,S0805
C85, C88, C89, C119, C134, C135, R3, R476, R477 3 S25003-2000SMT RESISTOR,SMD,1W,200OHMS,1% R416 1 S25000-2210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
35 S25020-27SMT CAPACITOR,SMD,CER,0.1MF,50V,-20%+80%,Z5U,S0805
C138, C149, C249, C267, C268, C271, R4 1 S25003-1210SMT RESISTOR,SMD,1W,121OHMS,1%

R420, R445 2 S25000-5110SMT RESISTOR,SMD,METAL FILM,1/10W,511OHMS,1%,S0805

C282, C298, C300, C301, C302, C328, R6, R12, R15, R21, R24, R510 6 S25013-1SMT RESISTOR,ARRAY,SMD,MF,1/16W,22OHM,8-PIN R421, R447, R454 3 S25012-1501SMT RESISTOR,SMD,METAL FILM,1/16W,1.50K,1%,S0603
C329, C343, C344
R30, R33, R61, R65, R124, R125, R196, R430, R437 2 S25001-15R0SMT RESISTOR,SMD,15.0OHMS,1/4W,1206,1%,TR
C25, C26, C29, C32, C293 5 S25020-5SMT CAPACITOR,SMD,CERAMIC,2700pF,50V,5%,X7R,S0805
R210, R302, R307, R335, R354, R407, 19 S25012-1002SMT RESISTOR,SMD,METAL FILM,1/16W,10.0K,1%,S0603 R435, R451 2 S25012-2211SMT RESISTOR,SMD,METAL FILM,1/16W,2.21K,1%,S0603
C30, C31, C169, C256, C283, C286,
8 S25020-3SMT CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805 R432, R439, R529, R530, R586, R587 R442, R446 2 S25001-1821SMT RESISTOR,SMD,1.82K,1/4W,1206,1%,TR
C288, C291
C39, C90, C92, C99, C131, C180, R450 1 S25000-2430SMT RESISTOR,SMD,METAL FILM,1/10W,243OHMS,1%,S0805
R31, R38, R62, R64, R150, R312 6 S25012-1503SMT RESISTOR,SMD,METAL FILM,1/16W,150K,1%,S0603 R452 1 S25012-3162SMT RESISTOR,SMD,METAL FILM,1/16W,31.6K,1%,S0603
C183, C185, C188, C223, C227, C228, 15 S25020-32SMT CAPACITOR,SMD,CERAMIC,10MF,6.3V,20%,X5R,S0805
C244, C304, C348
R32, R36, R52, R55, R152, R158, R172, R457, R458, R460, R462 4 S25003-20R0SMT RESISTOR,SMD,1W,20.0OHMS,1%
C40, C42, C45, C46, C47, C48, C50, R174, R175, R178, R290, R293, R299, 18 S25012-1003SMT RESISTOR,SMD,METAL FILM,1/16W,100K,1%,S0603 R463, R466, R469, R472 4 S25012-6810SMT RESISTOR,SMD,METAL FILM,1/16W,681OHMS,1%,S0603
C51, C52, C53, C57, C91, C93, C94, R303, R305, R309, R433, R453 R485 1 S25000-7500SMT RESISTOR,SMD,METAL FILM,1/10W,750OHMS,1%,S0805
C95, C96, C97, C98, C100, C101, R34, R313, R378, R379, R380, R382, N.G.3, N.E.2 S1, S2, S3 3 S19869-43 SWITCH_SLIDE_3PSTX1
C102, C103, C104, C105, C106, C107, R385, R387, R429, R436, R464, R467, T1 1 S25067-13SMT IC,SMD,TRANSFORMER MODULE,10/100BASE-T LAN MAGNETICS
19 S25012-1000SMT RESISTOR,SMD,METAL FILM,1/16W,100OHMS,1%,S0603
C108, C109, C111, C112, C113, C114, R470, R473, R594, R595, R609, R610, T2 1 S20375-24 TRANSFORMER,PWM,FLYBACK,ICE-1513
C130, C133, C141, C142, C143, C144, R611 X1 1 S25065-12SMT IC,SMD,CMOS,BUFFER,SINGLE-BUS(SS)
C145, C146, C147, C148, C150, C151,
R35, R71, R89, R92, R94, R106, R107, X4, X92, X100 3 S25072-2SMT IC,SMD,ACT,BUFFER,OCTAL,3-STATE,TSSOP-20(SS)
C152, C153, C154, C155, C156, C157,
C158, C159, C160, C161, C162, C163,
R110, R192, R211, R213, R214, R216, X5 1 M15102-4SMT IC,SMD,ARRAY,DRIVER,PERIPHERAL,NPN,DARLINGTON
C164, C165, C166, C167, C177, C178, R218, R219, R220, R221, R222, R223, X8 1 S25068-24SMT IC,SMD,REGULATOR,1.2V-5V,TPS72501(SS)
C179, C182, C186, C187, C189, C190, R224, R225, R227, R230, R231, R232, X9, X10, X12, X26, X38, X85 6 S15128-28SMT IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
C191, C193, C195, C196, C197, C198, R233, R234, R238, R239, R321, R322, X11 1 S25067-2SMT IC,SMD,CMOS,MULTILPLEXER,DIFF,4-1 CHANNEL
144 S25020-30SMT CAPACITOR,SMD,CERAMIC,0.22MF,10V,10%,X7R,S0603
C200, C201, C202, C203, C204, C205, R343, R348, R349, R350, R352, R353, X13 1 S24841-3 IC,MODULE,CONVERTER,DC-DC,5V/0.15A-OUT,5.25V-IN
71 S25012-3321SMT RESISTOR,SMD,METAL FILM,1/16W,3.32K,1%,S0603
C206, C207, C208, C209, C210, C211, R355, R375, R376, R377, R383, R386, X14, X15, X67 3 S20353-4SMT IC,SMD,CMOS,XCVR,EIA485(SS)
C212, C213, C215, C217, C218, C219, R389, R426, R475, R496, R497, R498, N.A.2 X18 1 S25070-22SMT IC,SMD,CMOS,CPLD,XC9572XL,BGA-48(SS)
C220, C229, C230, C231, C232, C233, R499, R500, R501, R513, R514, R515, X19 1 S25070-20SMT IC,SMD,FPGA,EP1C6F256I8,256-PIN,BGA(SS)
C234, C235, C236, C237, C238, C239, R516, R517, R518, R519, R520, R521, X20 1 S25073-5SMT IC,SMD,CMOS,DSP,32-BIT,179-PIN BGA,TMS320F2812(SS)
C240, C241, C242, C243, C262, C264,
R522, R523, R524, R525, R527, R569, X21, X36 2 S25057-5SMT POT,SMD,DIGITAL,20K,QUAD,TSSOP-24
C266, C269, C270, C272, C273, C274,
R606, R607, R608, R613 X22, X34, X74 3 S15128-11SMT IC,SMD,COMPARATOR,QUAD,2901D
C278, C279, C280, C281, C305, C306,
C309, C310, C311, C312, C314, C315, R39, R44, R45, R48, R49, R50, R51, X24 1 S15018-11SMT IC,SMD,CMOS,SWITCH,ANALOG,QUAD,201(SS)
8 S25001-5622SMT RESISTOR,SMD,56.2K,1/4W,1206,1%,TR X25 1 S15128-13SMT IC,SMD,OP-AMP,SINGLE,PRECISION,OP-27GS8,SOIC-8
C320, C321, C322, C327, C335, C336, R53
C337, C359, C360, C361, C362, C363, R41, R43, R47, R54 4 S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805 X28 1 S25069-22SMT IC,SMD,CMOS,EEPROM,SERIAL,512K,2.7V,SOIC-8M(SS)
C364, C365, C366, C367 R42, R162 2 S25012-1004SMT RESISTOR,SMD,METAL FILM,1/16W,1.00M,1%,S0603 X29 1 S25069-21SMT IC,SMD,CMOS,NVRAM,256MB,SOIC-14(SS)
C41, C43, C44, C71, C72, C171, C174, R46, R167 2 S25012-6191SMT RESISTOR,SMD,METAL FILM,1/16W,6.19K,1%,S0603 N.A.3 X32 1 S25069-19SMT IC,SMD,3V,MEMORY,FLASH,128Mb,BGA64,(SS)
12 S25020-24SMT CAPACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206
C216, C251, C257, C285, C290 R56, R203, R440 3 S25012-2001SMT RESISTOR,SMD,METAL FILM,1/16W,2.00K,1%,S0603 X33, X62, X72, X73 4 S25068-23SMT IC,SMD,VOLTAGE REGULATOR,4.5V-20V,TPS54350
C56, C61, C168, C246, C250, C254, X35, X46, X51, X53 4 S25069-18SMT IC,SMD,CMOS,SDRAM,64MB,TSOP54(SS)
11 S25020-10SMT CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805 R57, R58, R336, R406 4 S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
C284, C289, C345, C346, C347
R59, R200 2 S25012-3322SMT RESISTOR,SMD,METAL FILM,1/16W,33.2K,1%,S0603 X39, X40, X65, X79 4 S25065-6SMT IC,SMD,CMOS,INVERTER,SCHMITT,DUAL(SS)
C73, C181, C184, C263, C265, C316,
7 S25020-15SMT CAPACITOR,SMD,CERAMIC,22PF,50V,5%,COG,S0805 R60, R63, R235, R236, R237, R248, X41, X71 2 S15128-10SMT IC,SMD,VOLTAGE REF,ADJ, PRECISION,431I,SOIC-8
C317 8 S25012-6811SMT RESISTOR,SMD,METAL FILM,1/16W,6.81K,1%,S0603
C77, C132, C296, C299, C303 5 S25020-13SMT CAPACITOR,SMD,CERAMIC,150pF,100V,5%,COG,S0805 R414, R418 X47 1 S25073-6SMT IC,SMD,CMOS,MCU,32-BIT,BGA,388-PIN(SS)
C80 1 S25020-41SMT CAPACITOR,SMD,CERAMIC,560pF,50V,5%,COG,S0805 R73 1 S25000-6812SMT RESISTOR,SMD,METAL FILM,1/10W,68.1K,1%,S0805 X48 1 S25070-21SMT IC,SMD,CMOS,TRANSCEIVER,ETHERNET,PBGA-64(SS)
C110, C255, C287, C292, C325 5 S25020-29SMT CAPACITOR,SMD,CERAMIC,10MF,25V,20%,X5R,S1210 R75 1 S25000-1003SMT RESISTOR,SMD,METAL FILM,1/10W,100K,1%,S0805 N.A.4 X49 1 S25070-18SMT IC,SMD,EPROM,CLOCK-GENERATOR,CY2292(SS)
C120, C129, C247, C294, C307, C313, R78 1 S25000-2212SMT RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805 X50 1 S25073-10SMT IC,SMD,CMOS,DSP,BGA,288-PIN,TMS320C6413(SS)
8 S25020-33SMT CAPACITOR,SMD,CERAMIC,10MF,10V,20%,X5R,S1206
C323, C324 R81, R83, R85, R93, R96, R98, R100, X52 1 S25068-10SMT IC,SMD,VOLTAGE REGULATOR,FIXED,3-TERMINAL,0.5A,-15V
C170, C258 2 S25020-38SMT CAPACITOR,SMD,CERAMIC,100MF,6.3V,20%,X5R,S1206 13 S25001-2210SMT RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR X54 1 S15128-5SMT IC,VOLT REG,SMD,FIXED,3-T,(+),1A,5V
R260, R266, R479, R584, R585, R591
C172, C221, C222, C226, C253, C260, X57, X59, X70 3 S25068-16SMT IC,SMD,VOLT.REGULATOR,ADJ,0.8A,LM1117(SS)
7 S25020-22SMT CAPACITOR,SMD,CERAMIC,0.01MF,200V,20%,X7R,S1206 R84, R86, R87, R88, R90, R102, R128,
C349 9 S25001-4750SMT RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR X58, X60, X61 3 S25065-5SMT IC,SMD,CMOS,INVERTER,SCHMITT,SINGLE(SS)
C173, C259, C338, C339, C340 5 S25020-14SMT CAPACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805 R132, R592
X63 1 S25068-25SMT IC,SMD,VOLTAGE-REFERENCE,1.2V,0.2%,SOT-23(SS)
C224, C225 2 S25020-31SMT CAPACITOR,SMD,CERAMIC,270pF,100V,5%,COG,S0805 R91, R95 2 S25001-1211SMT RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
X64 1 S25068-4SMT IC,SMD,TRANSCEIVER,CAN,UC5350,S0IC-8
C245, C248 2 S25020-8SMT CAPACITOR,SMD,CERAMIC,0.056MF,50V,10%,X7R,S0805 R97, R99, R183 3 S25001-2211SMT RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
C252 1 S25020-25SMT CAPACITOR,SMD,CERAMIC,4.7MF,16V,10% ,X7R,S1210
X68 1 S25065-4SMT IC,SMD,CMOS,TRANSCEIVER,3V-5.5V,MAX3221,(SS)
R101, R191, R288, R431, R438 5 S25012-4750SMT RESISTOR,SMD,METAL FILM,1/16W,475OHMS,1%,S0603
C295 1 S25020-6SMT CAPACITOR,SMD,CERAMIC,4700pF,50V,5%,COG,S1206 X69 1 M15458-4SMT IC,SMD,PWM-CONTROLLER,I-MODE,2842A, SOIC-8
R103 1 S25000-2672SMT RESISTOR,SMD,METAL FILM,1/10W,26.7K,1%,S0805
C297 1 S25020-12SMT CAPACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805 X75 1 S25065-7SMT IC,SMD,CMOS,INVERTER,SINGLE(SS)
R108, R109, R115, R116, R120, R127,
D1, D2, D3, D4, D5, D6, D8, D38, D39, X77, X78 2 S25072-3SMT IC,SMD,ACT,BUFFER,OCT,3-STATE,3.3V,TSSOP-20(SS)
13 S25040-5SMT DIODE,SMD,DUAL,0.200A,70V,UFR R204, R319, R329, R332, R333, R338,
D40, D41, D48, D53 X81, X82, X83 3 S20353-7SMT IC,SMD,CMOS,XCVR,ADM1485(SS)
R367, R368, R369, R370, R371, R410,
D7, D9, D10, D11, D37, D44, D45, D46, X93, X94, X95, X96, X97, X98, X99 7 S25065-10SMT IC,SMD,CMOS,AND,SINGLE,2-INPUT(SS)
10 S25040-2SMT DIODE,SMD,1A,400V,DO-214BA/AC R413, R417, R483, R502, R503, R504, 38 S25012-1001SMT RESISTOR,SMD,METAL FILM,1/16W,1.00K,1%,S0603
D47, D54 Y1 1 S25082-6SMT CRYSTAL,SMD,32.768kHZ
D16, D17, D22, D23, D50 5 S25040-6SMT DIODE,SMD,DUAL,0.200A,70V,UDR,CC,SOT-23 R505, R506, R507, R508, R509, R526,
Y2, Y3 2 S25082-7SMT CRYSTAL,SMD,12MHZ
D19, D49, D52 3 S25049-4SMT DIODE,SMD,SCHOTTKY,DUAL,0.200A,30V,SOT-23 R557, R577, R578, R579, R580, R581,
D30 1 T12705-63 DIODE,SCHOTTKY,TO220,8A,100V,MBR10H100 R582, R583
D35 1 S25049-3SMT DIODE,SMD,SCHOTTKY,3A,40V,CASE 403-3 R111, R112, R117, R118, R121, R209,
D42 1 S25040-4SMT DIODE,SMD,DUAL,0.200A,70V,UFR 9 S25012-2212SMT RESISTOR,SMD,METAL FILM,1/16W,22.1K,1%,S0603
R388, R427, R434
D43, D55, D56, D57, D58 5 S25040-11SMT DIODE,SMD,1A,600V,S403A,ULTRA-FAST RECOVERY R126 1 S25000-4753SMT RESISTOR,SMD,METAL FILM,1/10W,475K,1%,S0805
DZ1, DZ2, DZ3, DZ4, DZ5, DZ6, DZ7,
9 S25046-1SMT ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123 R129 1 S25000-2211SMT RESISTOR,SMD,METAL FILM,1/10W,2.21K,1%,S0805
DZ8, DZ21
R130, R136 2 S25001-47R5SMT RESISTOR,SMD,47.5OHMS,1/4W,1206,1%,TR
DZ9, DZ10, DZ11, DZ12, DZ31, DZ32 6 S25044-9SMT ZENER DIODE,SMD,3W,6.2V,5%, SMB
DZ23 1 S25044-7SMT ZENER DIODE,SMD,3W,56V,5%, SMB R131 1 S25001-4751SMT RESISTOR,SMD,4.75K,1/4W,1206,1%,TR
R133, R134, R138, R139, R140, R144 6 S25000-1000SMT RESISTOR,SMD,METAL FILM,1/10W,100OHMS,1%,S0805 UNLESS OTHERWISE SPECIFIED:
DZ24 1 S25044-12SMT ZENER DIODE,SMD,3W,3.3V,5%, SMB
DZ26, DZ27, DZ28, DZ29, DZ30 5 S25046-3SMT ZENER DIODE,SMD,0.5W,18V, 5%,SOD123 R135, R137, R141, R142, R143, R145 6 S25001-3320SMT RESISTOR,SMD,332OHMS,1/4W,1206,1%,TR CAPACITANCE = MFD/VOLTS
R147, R201, R294, R320, R323 5 S25000-5620SMT RESISTOR,SMD,METAL FILM,1/10W,562OHMS,1%,S0805 INDUCTANCE = HENRIES
R155 1 S25000-3741SMT RESISTOR,SMD,METAL FILM,1/10W,3.74K,1%,S0805 RESISTANCE = OHMS
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) 2:1
POWER SOURCES PAGE ___ 3
3 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: fivory DOCUMENT DOCUMENT
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: EF
IF PRINTED
@ A1 SIZE SUBJECT: DIGITAL CONTROL P.C. BD. ASSEMBLY NUMBER: REVISION:

DO NOT SCALE THIS DRAWING APPROVED: BS
UNITS:
INCH
MATERIAL
DATE:
8/24/2012
PROJECT
NUMBER: CRM44934
REFERENCE:
G4800-3
G6682-1 F
machine.
Power Wave® S500

PFC CONTROL BOARD ASSEMBLY (G6860-1 PG 1)
G6860-1 ENGINEERING CONTROLLED CHANGE DETAIL: ADDED TABLE AND NOTES PER TABLE. REVISED NOTE N.E.1 ITEM QTY PART NUMBER DESCRIPTION
MANUFACTURER: Yes 1 1 G6860-D PC BOARD BLANK REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
N.E.4 2 2 E3768-4 LABEL 0.25 X 2.50
REFERENCES QTY PART NUMBER DESCRIPTION
N.E.3 3 224 g. E2527 EPOXY ENCAPSULATING RESIN
REVISION CONTROL 4 1 M19436-24 POTTING TRAY R11,
R26,
R12, R18, R20, R25,
R38, R39, R53, R55,
N.E.1 5 7 g. E2543 ELECTRICAL INSULATING COMPOUND 17 S25012-4752SMT RESISTOR,SMD,METAL FILM,1/16W,47.5K,1%,S0603
R61, R62, R63, R64, R87,
G6860-1D3 N.A.2 6 2 S8025-80 #6 SELF TAPPING SCREW
R88, R109
N.A.3 7 1 Y00562-02 SOFTWARE
PART NO. IDENTIFICATION N.A.4 8 1 Y01623-03 SOFTWARE R14, R16, R27, R44, R92,
6 S25001-5110SMT RESISTOR,SMD,511OHMS,1/4W,1206,1%,TR
CODE R110
REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW
TEST PER E4734-IC R15, R30, R47, R50, R222 5 S25001-1501SMT RESISTOR,SMD,1.5K,1/4W,1206,1%,TR
REFERENCES QTY PART NUMBER DESCRIPTION
POT WITH E2527
C1, C2, C3, C8, C9, C10, R23, R54 2 S25001-2210SMT RESISTOR,SMD,221OHMS,1/4W,1206,1%,TR
SCHEMATIC REFERENCE: G6859-1D3 C11, C21, C23, C24, C25, 13 S13490-173 CAPACITOR,PEMF,1.0,63V,10% R28, R31, R45, R48 4 S25001-1002SMT RESISTOR,SMD,10K,1/4W,1206,1%,TR
MAKE DETAIL C26, C27 R29, R32, R46, R49,
8 S25001-4750SMT RESISTOR,SMD,475OHMS,1/4W,1206,1%,TR
C4, C5, C6, C7 4 S25024-9SMT CAPACITOR,SMD,TANTALUM,100MF,20V,20%,S7343 R138, R139, R140, R141
MANUFACTUREPERE1911-RoHS C12, C20 2 S25020-1SMT CAPACITOR,SMD,CERAMIC,0.022MF,50V,1%,COG,S1825 R33, R34, R165 3 S25001-1000SMT RESISTOR,SMD,100OHMS,1/4W,1206,1%,TR
BUY BLANK COMPLETE CAPACITOR,SMD,TANTALUM,100MF,16V,20%,S7343,LOW- R40, R60 2 S25000-1821SMT RESISTOR,SMD,METAL FILM,1/10W,1.82K,1%,S0805
C13, C15, C17 3 S25026-2SMT
ESR,SURGE R56, R68 2 S25000-1001SMT RESISTOR,SMD,METAL FILM,1/10W,1.00K,1%,S0805
(4 BOARDS PER PANEL) C14, C16 2 S25024-10SMT CAPACITOR,SMD,TANTALUM,22MF,25V,10%,S7343 R57, R84, R86, R91,
4 LAYER BOARD BLANK PANEL R119, R134, R154, R169, 9 S25000-1002SMT RESISTOR,SMD,METAL FILM,1/10W,10.0K,1%,S0805
SEE ELECTRONIC FILE FOR ADDITIONAL INFORMATION. C18, C28, C36, C37, C38, R170
C42, C43, C44, C45, C46, R70, R94, R125, R142 4 S25012-4751SMT RESISTOR,SMD,METAL FILM,1/16W,4.75K,1%,S0603
C47, C48, C54, C55, C56,
R72, R95 2 S25012-2671SMT RESISTOR,SMD,METAL FILM,1/16W,2.67K,1%,S0603
C57, C58, C59, C62, C63,
R73, R96, R111, R112 4 S25000-2431SMT RESISTOR,SMD,METAL FILM,1/10W,2.43K,1%,S0805
C72, C76, C77, C78, C79,
6.84 R75, R76, R77, R78, R79,
C82, C83, C84, C89, C90, 49 S25020-3SMT CAPACITOR,SMD,CERAMIC,0.1MF,50V,10%,X7R,S0805
R80, R81, R153, R155,
C91, C92, C93, C94, 14 S25001-15R0SMT RESISTOR,SMD,15.0OHMS,1/4W,1206,1%,TR
C100, C119, C120, C125,
R156, R157, R158, R160,
6.50 R161
C128, C131, C132, C136,
C141, C142, C143, C145, R90 1 S25000-2212SMT RESISTOR,SMD,METAL FILM,1/10W,22.1K,1%,S0805
R93, R98, R145, R146 4 S25012-1503SMT RESISTOR,SMD,METAL FILM,1/16W,150K,1%,S0603

C146, C147, C149

N.E.1 N.E.1 R97, R123, R131, R143,
5 S25012-1000SMT RESISTOR,SMD,METAL FILM,1/16W,100OHMS,1%,S0603
C19, C35, C150 3 S25020-15SMT CAPACITOR,SMD,CERAMIC,22PF,50V,5%,COG,S0805 R147
C22, C41, C49, C73, C81, R99, R100, R101, R102,
4 C121, C138, C139
8 S25020-2SMT CAPACITOR,SMD,CERAMIC,0.022MF,50V,10%,X7R,S0805
R103, R104, R126, R127
8 S25001-26R7SMT RESISTOR,SMD,26.7OHMS,1/4W,1206,1%,TR
FTP25
C4 C6 C29, C30, C32 3 S13490-197 CAPACITOR,ALEL,82,35V,20%,LOW-ESR R105 1 S25000-5622SMT RESISTOR,SMD,METAL FILM,1/10W,56.2K,1%,S0805

FTP27
J23A FTP9 FTP7 J23B C31 1 S20500-1 CAPACITOR,PPMF,0.1,1000V,10%,BOX R106, R207, R208 3 S25000-3322SMT RESISTOR,SMD,METAL FILM,1/10W,33.2K,1%,S0805
R7
R8
R3
R4
D9 D11
C33 1 S13490-230 CAPACITOR,ALEL,220,63V,20% R107, R132, R133, R206,
D17
D8
C5
C34 1 S13490-198 CAPACITOR,ALEL,1000,35V,20%,LOW-ESR
6 S25001-2211SMT RESISTOR,SMD,2.21K,1/4W,1206,1%,TR
D22
D21
D5 D6 D7 D18 D19 D20

C7
R209, R210
D2
D1
Q10
T1
FTP19
FTP8
X7
N.E.1
FTP28
X1 C39, C66, C74, C75 4 S25020-27SMT CAPACITOR,SMD,CER,0.1MF,50V,-20%+80%,Z5U,S0805 R108, R221 2 S25000-2672SMT RESISTOR,SMD,METAL FILM,1/10W,26.7K,1%,S0805
C8
C9
X2 X3 D10 D12 X5 X6 Q1
C2
C3
D23
D24
D3
D4
Q9
Q2
C40, C50, C64, C65, C67, R115, R116, R252, R253,
FTP16
C20
C68, C69, C70, C71, 11 S25020-6SMT CAPACITOR,SMD,CERAMIC,4700pF,50V,5%,COG,S1206 6 S25012-1002SMT RESISTOR,SMD,METAL FILM,1/16W,10.0K,1%,S0603
D14
D16
R254, R255
C12
C1 X4 C10
DZ1
DZ2
DZ3
DZ4
DZ5
DZ6
DZ7
DZ8
C122, C151 R118, R120, R121, R135 4 S25012-1501SMT RESISTOR,SMD,METAL FILM,1/16W,1.50K,1%,S0603

C11
C24
C25
C23
C21
D13
D15
X8 X12 C51, C53, C60, C61,

D25
5 S25020-14SMT CAPACITOR,SMD,CERAMIC,330pF,100V,5%,COG,S0805 R124, R152 2 S25012-1212SMT RESISTOR,SMD,METAL FILM,1/16W,12.1K,1%,S0603

L1
OCI1 OCI2 OCI3 OCI4

D28 D29 C148
R128, R159, R162, R163,
D43
D44
J24
X18 X19 X17 X16

C52 1 S25020-22SMT CAPACITOR,SMD,CERAMIC,0.01MF,200V,20%,X7R,S1206 6 S25001-1503SMT RESISTOR,SMD,150K,1/4W,1206,1%,TR
FTP23
R257
D26 D27
R65
C13 C14
2 R164, R202
DZ10
FTP20
FTP21
C19
Q4
C80, C101, C130 3 S25020-12SMT CAPACITOR,SMD,CERAMIC,100pF,100V,5%,COG,S0805

D45
D46
D47
D48
C35
Y2
D30
D31
D41
D42
D39
D40
X31 FTP5 R129, R130, R214 3 S25001-1001SMT RESISTOR,SMD,1K,1/4W,1206,1%,TR

C15
X13 X14
C85, C86, C87, C88, C95,
LED2
C17
1
N.E.4 R136 1 S25000-1500SMT RESISTOR,SMD,METAL FILM,1/10W,150OHMS,1%,S0805
FTP35
FTP37
LED5
FTP36
FTP33
FTP34
C27
C26
J2
FTP14
FTP4
C96, C97, C98, C99, R148, R149 2 S25000-2801SMT RESISTOR,SMD,METAL FILM,1/10W,2.80K,1%,S0805

FTP26
Y1
FTP13
C22
C16
C102, C103, C104, C105,
FTP31 FTP32
FTP15 1 J1 X20 R166, R223, R224, R225,

X22
C106, C107, C108, C109,

D52
D53
D54
D55
R226, R227, R228, R229,

DZ9
X21
Q3 D49 FTP6 33 S25020-30SMT CAPACITOR,SMD,CERAMIC,0.22MF,10V,10%,X7R,S0603
6.49 6.15 X24 C110, C111, C113, C114, R230, R231, R232, R233,
FTP38
FTP10
C115, C116, C117, C118,

J25
C74
R56
R57
X10
R234, R235, R236, R237, 25 S25001-2213SMT RESISTOR,SMD,221K,1/4W,1206,1%,TR
FTP24
LED1
X26 OCI5
FTP12 C124, C126, C133, C135,
FTP18
FTP22
R238, R239, R240, R241,

C39
R92
FTP11
DZ11
R86
X25
C155, C156, C157, C158
J22
FTP2 R242, R243, R244, R245,

C66
R91
DZ12
DZ17
C123, C127 2 S25020-33SMT CAPACITOR,SMD,CERAMIC,10MF,10V,20%,X5R,S1206 R246

FTP30
DZ18
R110
X27
LED3
FTP1
D36 D33 D35 D38 D34 D37

R84
D51
FTP17
C129 1 S25024-8SMT CAPACITOR,SMD,TANTALUM,10MF,16V,10%,S6032 R167, R168, R171, R172 4 S25000-47R5SMT RESISTOR,SMD,METAL FILM,1/10W,47.5OHMS,1%,S0805
D64
N.E.1 DZ19 D56 C137, C140, C144 3 S25020-13SMT CAPACITOR,SMD,CERAMIC,150pF,100V,5%,COG,S0805 R173, R174, R175, R217 4 S25001-2001SMT RESISTOR,SMD,2K,1/4W,1206,1%,TR
D58
X9 C30
D50
C29 Q8
DZ20 D57 C31
N.E.1 C152, C153 2 S25020-24SMT CAPACITOR,SMD,CERAMIC,1.0MF,25V,10% ,X7R,S1206 R176, R211 2 S25000-4751SMT RESISTOR,SMD,METAL FILM,1/10W,4.75K,1%,S0805
FTP29 FTP40
J21
C154 1 S25020-35SMT CAPACITOR,SMD,CERAMIC,680pF,50V,5%,COG,S0805 R177 1 S25012-2212SMT RESISTOR,SMD,METAL FILM,1/16W,22.1K,1%,S0603

D62
C159, C160, C161 3 S25020-10SMT CAPACITOR,SMD,CERAMIC,4700pF,50V,10%,XR7,S0805 R178, R212 2 S25006-10R0SMT RESISTOR,SMD,METAL FILM,1/2W,10OHMS,1%,S2010
D59
C162, C163 2 S25020-43SMT CAPACITOR,SMD,CERAMIC,2.2MF,10V,10%,X7R,S0805 R185, R189 2 S25012-5111SMT RESISTOR,SMD,METAL FILM,1/16W,5.11K,1%,S0603

D68
D65
D63
X29 X30 Q7
D1, D2, D3, D4, D5, D6, R186, R187 2 S25001-1211SMT RESISTOR,SMD,1.21K,1/4W,1206,1%,TR
T2
D61
J26
D7, D8, D13, D14, D15,

D60
R197, R199, R200, R201 4 S25012-1213SMT RESISTOR,SMD,METAL FILM,1/16W,121K,1%,S0603

6
DZ22
J20
C32
R2
D67 D66 D16, D17, D18, D19, D20,

28 S25049-2SMT DIODE,SMD,SCHOTTKY,1A,30V,SMA R198, R204 2 S25012-1502SMT RESISTOR,SMD,METAL FILM,1/16W,15.0K,1%,S0603
C33 D21, D22, D23, D24, D30,
Q6 R203, R205 2 S25001-1213SMT RESISTOR,SMD,121K,1/4W,1206,1%,TR
C34
N.A.2 D31, D39, D40, D41, D42,
G6860-1 R213 1 S25001-3321SMT RESISTOR,SMD,3.32K,1/4W,1206,1%,TR
D43, D44
R210
R209
R212
LED4
D69
R215 1 S25000-4753SMT RESISTOR,SMD,METAL FILM,1/10W,475K,1%,S0805

FTP3
D9, D10, D11, D12, D26, R216, R218 2 S25000-5111SMT RESISTOR,SMD,METAL FILM,1/10W,5.11K,1%,S0805
D27, D28, D29, D45, D46, R219 1 S25000-3922SMT RESISTOR,SMD,METAL FILM,1/10W,39.2K,1%,S0805
D47, D48, D49, D50, D52, 23 S25040-1SMT DIODE,SMD,1A,400V,FAST RECOVERY,DO-214BA R220 1 S25000-6811SMT RESISTOR,SMD,METAL FILM,1/10W,6.81K,1%,S0805
D53, D54, D55, D56, D57, R248, R249, R250, R251 4 S25000-2210SMT RESISTOR,SMD,METAL FILM,1/10W,221OHMS,1%,S0805
N.P.T.2
D58, D65, D68 R256, R257, R258, R259 4 S25000-2670SMT RESISTOR,SMD,METAL FILM,1/10W,267OHMS,1%,S0805
D25 1 S25049-3SMT DIODE,SMD,SCHOTTKY,3A,40V,CASE 403-3 T1 1 S13000-123 TRANSFORMER,GATE-DRIVE,PCB,58P60
T2 1 S20375-40 TRANSFORMER,FLYBACK,AF5175
COMPONENT SIDE D32, D66, D67 3 S25049-1SMT DIODE,SMD,SCHOTTKY,0.5A,30V,SOD-123
D33, D34, D35, D36, D37, X1, X7, X25 3 S15128-28SMT IC,OP-AMP,SMT,QUAD,HIGH-PERF,33074ADT
6 S25049-4SMT DIODE,SMD,SCHOTTKY,DUAL,0.200A,30V,SOT-23
D38 X2, X3, X5, X6, X16, X17,
SCALE = 1:1 D51 1 T12705-58 DIODE,D204AL,1A,1500V X18, X19
8 S15018-21SMT IC,SMD,CMOS,DRIVER,MOSFET,4451, SOIC-8(SS)
D59, D60, D61, D69 4 S25040-8SMT DIODE,SMD,3A,600V,D0-214AB,ULTRA-FAST RECOVERY X4, X8, X12 3 S25068-40SMT IC,SMD,DRIVER,DUAL,LOW-SIDE,4424YM,SOIC-8(SS)
D62, D63, D64 3 S25040-18SMT DIODE,SMD,1A,1300V,DO-214BA X9 1 S25068-6SMT IC,SMD,VOLT REG,FIXED,3-T,(+),0.1A,5V,SOIC-8
DZ1, DZ2, DZ3, DZ4, DZ5, X10 1 S25084-5SMT TEMPERATURE SENSOR,SMD,TMP20
9 S25046-1SMT ZENER DIODE,SMD,0.5W,5.1V, 5%,SOD123
DZ6, DZ7, DZ8, DZ9 X13 1 S25068-12SMT IC,SMD,VOLTAGE REGULATOR,3A,+5V,SO8
ASSEMBLY NOTES: DZ10, DZ17, DZ18, DZ22 4 S25044-5SMT ZENER DIODE,SMD,3W,18V,5%, SMB X14 1 S25068-39SMT IC,SMD,VOLTAGE REGULATOR,DUAL OUTPUT,TPS70102
DZ11, DZ12 2 S25046-4SMT ZENER DIODE,SMD,0.5W,12V,5%,SOD-123
X20 1 S15128-11SMT IC,SMD,COMPARATOR,QUAD,2901D
N.A.2 SECURE P.C. BOARD ASSEMBLY IN PLACE WITH ITEM 6 (2 PLACES). TIGHTEN UNTIL SCREW HEAD DZ19, DZ20 2 S25044-9SMT ZENER DIODE,SMD,3W,6.2V,5%, SMB
X21 1 S25065-5SMT IC,SMD,CMOS,INVERTER,SCHMITT,SINGLE(SS)
TOUCHES BOARD AND THEN BACK OFF 1/2 TURN. J1, J2 2 S26770-10SMT CONNECTOR,SMD,SOCKET,LOW-PROFILE,10-PIN
N.A.4 X22 1 S25073-27SMT IC,SMD,CMOS,DSP,32-BIT,176-PIN,PQFP,TMS320F28235(SS)
N.E.1 J20, J21 2 S24020-4 CONNECTOR,MOLEX,MINI,PCB,4-PIN,TIN
N.A.3 X24 1 S25070-26SMT IC,SMD,CMOS,CPLD,EPM570T100I5(SS)
N.A.3 PROGRAM X24 WITH ITEM 7 (AFTER ASSEMBLY). N.E.1 J22, J26 2 S24020-6 CONNECTOR,MOLEX,MINI,PCB,6-PIN,TIN
N.E.1 J24 1 S24020-8 CONNECTOR,MOLEX,MINI,PCB,8-PIN,TIN
X26 1 S25070-35SMT IC,SMD,CMOS,ISOLATOR,DIGITAL,2201(SS)
N.A.4 PROGRAM X22 WITH ITEM 8 (AFTER ASSEMBLY). N.E.1 J25 1 S24020-12 CONNECTOR,MOLEX,MINI,PCB,12-PIN,TIN X27 1 S20353-4SMT IC,SMD,CMOS,XCVR,EIA485(SS)
N.E.1 J23A, J23B 2 S24020-16 CONNECTOR,MOLEX,MINI,PCB,16-PIN,TIN X29 1 S25068-38SMT IC,SMD,CMOS,DRIVER,MOSFET,2213S,SOIC-16(SS)
L1 1 S25083-3SMT CHOKE,SMD,POWER,47UH,10%,1.25A, X30 1 M15458-15SMT IC,SMD,PWM-CONTROLLER,I-MODE,28C44D,SOIC-8
ENVIRONMENTAL NOTES: LED1 1 S25080-4SMT LED,SMD,BI-COLOR,RED/GREEN,HSMF-C655 X31 1 S25069-17SMT IC,SMD,CMOS,EEPROM,SERIAL,SPI,16KX8,2.7V,SOIC-8
LED2, LED5 2 S25080-1SMT LED,SMD,RED,CLEAR,S1206 Y1 1 S25082-9SMT OSCILLATOR,SMD,20.000MHZ
N.E.1 PRIOR TO POTTING, CONNECTORS MUST BE GREASED WITH ITEM 5. LED3, LED4 2 S25080-2SMT LED,SMD,GREEN,CLEAR,S1206 Y2 1 S25082-11SMT CRYSTAL,SMD,30MHZ
OCI1, OCI2, OCI3, OCI4 4 S15000-28SMT OPTOCOUPLER,SMD,TTL-OUT,HI-SPD,HI-CMR
N.E.3 DISPENSE POTTING MATERIAL TO A MINIMUM DEPTH SUCH THAT ALL COMPONENT LEADS ARE OCI5 1 S15000-22SMT OPTOCOUPLER,SMD,PHOTO-TRANSISTOR,70V,CNY1733SD
COVERED.
Q1, Q2, Q3, Q9, Q10 5 S25051-4SMT TRANSISTOR,SMD,NMF,SOT-23,0.115A,60V,7002LT1(SS)
Q4 1 S25051-6SMT TRANSISTOR,SMD,NMF,DPAK,TO-252,10A,100V(SS)
N.E.4 PLACE BAR CODED ASSEMBLY NUMBER AND BAR CODED SERIAL NUMBER IDENTIFICATION IN AREA
Q6, Q8 2 S27524 HEAT SINK ASSEMBLY,T12704-117 & S20590-3 (SS)
SHOWN.
Q7 1 S25050-2SMT TRANSISTOR,SMD,PNP,SOT23,0.5A, 40V,MMBT4403LT1
R1, R10, R19, R21, R22, ALL COMPONENTS AND MATERIALS USED IN THIS
GENERAL NOTES: R24, R35, R36, R37, R41,
R42, R43, R51, R52, R58,
27 S25012-3321SMT RESISTOR,SMD,METAL FILM,1/16W,3.32K,1%,S0603
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253.
N.G.1. CAUTION: THIS ASSEMBLY IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY. R59, R65, R66, R67, R69,
SEE E2454 BEFORE HANDLING. THIS ASSEMBLY IS NO LONGER ESD SENSITIVE AFTER POTTING. R82, R83, R85, R89,
PART NO. TABLED NOTES R113, R114, R137

G6860-1D3HPT N.P.T.1., N.P.T.2. R2 1 S25014-0R10SMT RESISTOR,SMD,METAL-STRIP,5W,0.1OHM,1%
APPLICABLE DRAWING INFORMATION INDEX
G6860-1 NOTES PER TABLE: R3, R4, R7, R8 4 S25003-1210SMT RESISTOR,SMD,1W,121OHMS,1%
PAGE 1 PRODUCTION DRAWING
R5, R6, R13, R17 4 S25001-1210SMT RESISTOR,SMD,121OHMS,1/4W,1206,1%,TR
N.P.T.1. MAKE G6860-[LATEST VERSION]HPT BY TESTING PER SPECIAL TEST INSTRUCTIONS PER E4734-IC. R9, R74, R117, R151 4 S25012-1001SMT RESISTOR,SMD,METAL FILM,1/16W,1.00K,1%,S0603
PAGE 2 PRODUCTION DRAWING
M23003-26 SLIDE LINE WORK INSTRUCTIONS
N.P.T.2. PRINT “FOR PARTS ORDERS ONLY” ON E3768-4 LABEL AND PLACE ON SIDE OF POTTING TRAY M23003-27 PROGRAMMING INSTRUCTIONS
AS SHOWN. THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL:TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) SEE ABOVE
1 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: tsado DOCUMENT DOCUMENT
IF PRINTED
@ A1 SIZE SUBJECT: PFC CONTROL PC BOARD ASSEMBLY NUMBER: REVISION:

UNITS:
INCH
MATERIAL
DATE:
1/12/2013
PROJECT
NUMBER: CRM46440
REFERENCE:
-
G6860-1 D
machine.
Power Wave® S500

PFC CONTROL BOARD ASSEMBLY (G6860-1 PG 2)
G6860-1 ENGINEERING CONTROLLED CHANGE DETAIL: ADDED TABLE AND NOTES PER TABLE. REVISED NOTE N.E.1
MANUFACTURER: Yes
R17
FTP25
R6
C4 C6
FTP27
R26
R12
C41
R18
C49
R53
J23A J23B
R13
R5
FTP9 FTP7
R7
R8
R3
R4
C60
R55
R20
C61
D9 D11
R54
R23
C51
R11
R25
D17
D8
C53
R254
R250
C5
D22
D21
R62
D5 D6 D7 D18 D19 D20
D2
D1
C7 Q10
T1
C28
FTP19
X7
R253
R249
R252
R248
R63
C73
C37
C38
FTP8
FTP28
X1
C46
C45
C47
C48
C8
C9
R251
R60
R87
C36
X2 X3 D10 D12 X5 X6 Q1
C2
C3
D23
D24
C72
C42
C43
D3
D4
Q9
R14
C44
Q2
R255
R61
FTP16
C20
R64
R40
R39
C56
R88
D14
D16
R44
R16
C12
C1 X4 C10
DZ1
DZ2
DZ3
DZ4
R27
R28
R29
R30
R31
R15
R32
R45
R46
R47
R48
R49
R50
DZ5
DZ6
DZ7
DZ8
R38
R33
R34
C54
C57
C58
C59
C11
C24
C25
C23
C21
D13
D15
C55
C91
R67
R66
X8 X12
D25
L1
R52
R51
OCI1 OCI2 OCI3 OCI4
D28 D29
R114
R118
R113
R135
R120
R121
C92
C79
R89
C77
R69
C90
D43
D44
J24
R58
R59
C52
X18 X19 X17 X16
R75
R77
R80
R259
FTP23
R1
R258
R257
D27
R256
R82
R74
C81
D26
R65
R83
C13 C14
C62
C63
DZ10
FTP20
FTP21
C19
Q4
D45
D46
D47
D48
C35
C40
D32
R76
R78
R79
R81
R140
C18
Y2
D30
D31
D41
D42
D39
D40
C78
C76
C89
R73
R72
C82
R85
R9
C80
R70
X31 FTP5 R141
C15
C88
X13 X14 LED2
C17
R104
R103
R102
R127
R101
FTP35
FTP37
LED5
FTP36
FTP33
FTP34
R109
R108
R115
R116
R117
C27
C26
J2
C85
R98
R97
FTP14
C157
C133
C110
C156
C158
FTP4
C96
C95
R90
C93
R95
R96
C155
R107
C97
FTP26
Y1
R106
R105
FTP13
C94
C22
C16
R125
C119
FTP31 FTP32
R124
C100
C101
R100
R94
R93
FTP15 1 J1 X20
C117
C114
X22
R126
R128
C87
R99
C160
C159
C161
R35
R36
R37
R148
R151
D52
D53
D54
D55
R129
R130
DZ9
R177
C163
C162
R132
R133
C102
R131
C105
C135
R24
R22
C108
R123
R142
R146
X21
R21
R19
C98
Q3 D49 FTP6
R153
R155
R157
R160
R43
R42
R41
R137
C113
R163
C116
R147
X24
R134
R143
R145
FTP38
C104
C106
C107
C111
C103
C118
FTP10
C99
R10
C86
C115
J25
C109
R156
R158
R161
C74
R56
R57
C69
R152
R149
C121
R136
X10
FTP24
C83
C84
LED1
R164
X26 OCI5
C120
FTP12
FTP18
FTP22
R189
R154
R187
R159
R162
C122
C39
R92
FTP11
DZ11
R86
R138
X25
R139
R119
C68
J22
R112
R170
R165
C128
R111
R169
R168
R167
R172
R171
C146
C136
R186
R185
FTP2
C66
R91
DZ12
R197
C139
DZ17
FTP30
DZ18
R166
R173
R174
R202
R203
R205
C130
C131
R110
C123
X27
LED3
C124
C125
C126
FTP1
D36 D33 D35 D38 D34 D37
C64
C50
C70
C67
C71
C65
R84
D51
C75
R68
FTP17
R200
R206
D64
R204
R198
C137
C138
R199
R201
C140
C127
R178
DZ19 D56
D58
C129
R175
C153
X9 C30
D50
R176
C29 Q8
C132
DZ20 D57 C31
FTP29 FTP40
J21
R223
R229
R235
R241
D62
D59
R224
R230
R236
R242
C154
R215
C151
D68
D65
D63
X29 X30
C152
Q7
R221
R225
R231
R237
R243
T2
C144
R216
C148
R220
C150
D61
C143
C142
J26
D60
R222
R218
R219
C149
DZ22
J20
R226
R232
R238
R244
C32
R2
R213
R214
R217
D67 D66 R211
R207
R208
C141
C33
R227
R233
R239
R245
C145
C147
Q6
C34
R228
R234
R240
R246
G6860-1
R210
R209
R212
LED4
D69
FTP3
SCALE = 2:1
ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm) SEE ABOVE
2 OF ___
ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm) DRAWN BY: tsado DOCUMENT DOCUMENT
IF PRINTED
@ A1 SIZE SUBJECT: PFC CONTROL PC BOARD ASSEMBLY NUMBER: REVISION:

UNITS:
INCH
MATERIAL
DATE:
1/12/2013
PROJECT
NUMBER: CRM46440
REFERENCE:
-
G6860-1 D
machine.
Power Wave® S500

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View Safety Info

POWER WAVE ® S500

Need Help? Call 1.888.935.3877

For Service outside the USA:

SVM239-A | Issue D­ate 13-Oct

Downloaded from www.Manualslib.com manuals search engine

CALIFORNIA PROPOSITION 65 WARNINGS

FOR ENGINE 1.h. To avoid scalding, do not remove the

idler by pushing on the throttle control rods

POWER WAVE® S500

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ELECTRIC SHOCK can kill. ARC RAYS can burn.

• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

welding procedure and application involved. Worker expo-

5.e. Read and understand the manufacturerʼs instructions for this

5.f. Also see item 1.b.

POWER WAVE® S500

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WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

electrically “hot” parts to touch a cylinder.

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

Downloaded from www.Manualslib.com manuals search engine

6. Eloigner les matériaux inflammables ou les recouvrir afin de

prévenir tout risque dʼincendie dû aux étincelles.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

5. Toujours porter des lunettes de sécurité dans la zone de

POWER WAVE® S500

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Electromagnetic Compatibility (EMC)

Installation and Use

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

f) equipment used for calibration or measurement

POWER WAVE® S500

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Electromagnetic Compatibility (EMC)

Methods of Reducing Emissions

Maintenance of the Welding Equipment

Earthing of the Workpiece

Screening and Shielding

POWER WAVE® S500

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Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-690

POWER WAVE® S500

Downloaded from www.Manualslib.com manuals search engine

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2/A-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Select Suitable Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

SVM239-A | Issue Date 13-Oct