Power Wave R500: Operator's Manual

Operator’s Manual
POWER WAVE ® R500

For use with machines having Code Numbers:
11890
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Date Purchased no later than the following business day.
For Service outside the USA:

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Serial: (ex: U1060512345)
IM10133 | Issue Date 01/15

© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
WARNING properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 06/15/2016
SAFETY
SECTION A: 1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.
Keep hands, hair, clothing and tools away
WARNINGS from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines 1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
Diesel engine exhaust and some of its constituents are known necessary and replace them when the maintenance requiring
to the State of California to cause cancer, birth defects, and other their removal is complete. Always use the greatest care when
reproductive harm. working near moving parts.
Gasoline Engines 1.f. Do not put your hands near the engine fan. Do not attempt to
The engine exhaust from this product contains chemicals known override the governor or idler by pushing on the throttle control
to the State of California to cause cancer, birth defects, or other rods while the engine is running.
reproductive harm.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
ARC WELDING CAN BE HAZARDOUS. PROTECT as appropriate.
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
1.h. To avoid scalding, do not remove the radiator
INJURY OR DEATH. KEEP CHILDREN AWAY. pressure cap when the engine is hot.
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, ELECTRIC AND
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet MAGNETIC FIELDS MAY
E205 is available from the Lincoln Electric Company, BE DANGEROUS
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, 2.a. Electric current flowing through any conductor
MAINTENANCE AND REPAIR PROCEDURES ARE causes localized Electric and Magnetic Fields (EMF).
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician
before welding.
FOR ENGINE POWERED 2.c. Exposure to EMF fields in welding may have other health effects
EQUIPMENT. which are now not known.
1.a. Turn the engine off before troubleshooting 2.d. All welders should use the following procedures in order to
and maintenance work unless the minimize exposure to EMF fields from the welding circuit:
maintenance work requires it to be running. 2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
1.b. Operate engines in open, well-ventilated
2.d.2. Never coil the electrode lead around your body.
areas or vent the engine exhaust fumes outdoors.
2.d.3. Do not place your body between the electrode and work
1.c. Do not add the fuel near an open flame cables. If the electrode cable is on your right side, the
welding arc or when the engine is running. work cable should also be on your right side.
Stop the engine and allow it to cool before 2.d.4. Connect the work cable to the workpiece as close as pos-
refueling to prevent spilled fuel from sible to the area being welded.
vaporizing on contact with hot engine parts
2.d.5. Do not work next to welding power source.
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
Safety 02 of 04 - 06/15/2016
SAFETY
ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. 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 material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
CAN BE DANGEROUS.
with the workpiece or ground) use the following
5.a. Welding may produce fumes and gases
equipment:
hazardous to health. Avoid breathing these fumes and gases.
• Semiautomatic DC Constant Voltage (Wire) Welder. When welding, keep your head out of the fume. Use enough
• DC Manual (Stick) Welder. ventilation and/or exhaust at the arc to keep fumes and gases
• AC Welder with Reduced Voltage Control. away from the breathing zone. When welding hardfacing
(see instructions on container or SDS) or on lead
3.c. In semiautomatic or automatic wire welding, the electrode,
or cadmium plated steel and other metals or
electrode reel, welding head, nozzle or semiautomatic welding
coatings which produce highly toxic fumes, keep
gun are also electrically “hot”.
exposure as low as possible and within applicable
3.d. Always be sure the work cable makes a good electrical OSHA PEL and ACGIH TLV limits using local
connection with the metal being welded. The connection should exhaust or mechanical ventilation unless exposure
be as close as possible to the area being welded. assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical (earth) respirator may also be required. Additional
ground. precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected by
damaged insulation. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling. welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
3.h. Never simultaneously touch electrically “hot” parts of electrode thereafter to be certain it is within applicable OSHA PEL and
holders connected to two welders because voltage between the ACGIH TLV limits.
two can be the total of the open circuit voltage of both
welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
3.i. When working above floor level, use a safety belt to protect heat and rays of the arc can react with solvent vapors to form
yourself from a fall should you get a shock. phosgene, a highly toxic gas, and other irritating products.
3.j. Also see Items 6.c. and 8. 5.d. Shielding gases used for arc welding can displace air and cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 06/15/2016
SAFETY
WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used. • Away from areas where they may be struck or subjected
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of 7.f. Valve protection caps should always be in place and hand tight
Containers and Piping That Have Held Hazardous Substances”, except when the cylinder is in use or connected for use.
AWS F4.1 from the American Welding Society
7.g. Read and follow the instructions on compressed gas cylinders,
(see address above).
associated equipment, and CGA publication P-l, “Precautions for
6.e. Vent hollow castings or containers before heating, cutting or Safe Handling of Compressed Gases in Cylinders,” available from
welding. They may explode. the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
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.
Safety 04 of 04 - 06/15/2016
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications ............................................................................................... ........................A-1, A-2
Safety Precautions ............................................................................................................... ........................A-3
Location, Lifting ...........................................................................................................................................A-3
Stacking .......................................................................................................................................................A-3
Tilting ...........................................................................................................................................................A-3
Input and Ground Connections ................................ .....................................................................................A-3
Machine Grounding.......................................................................................................................................A-3
High Frequency Protection ............................................................................................................................A-3
Input Connection ..................................................................................................................................................A-4
Input Fuse and Supply Wire...........................................................................................................................A-4
Input Voltage Selection .................................................................................................................................A-4
Connection Diagram MIG Process .................................................................................................................A-5
Recommended Work Cable Sizes ..................................................................................................................A-6
Cable Inductance and its Effects on Welding .................................................................................................A-7
Remote Sense Lead Specifications ........................................................................................................A-7, A-8
Voltage Sensing Considerations for Multiple Arc System ......................................................................A-9, A-10
Control Cable Connections ..................................................................................................................................A-11
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ........................................................................................................................................B-1
Power-Up Sequence .............................................................................................................................B-1
Duty Cycle ............................................................................................................................................B-1
Graphic Symbols ..................................................................................................................................B-1
Product Description.......................................................................................................................................B-2
Recommended Processes and Equipment.....................................................................................................B-2
Equipment Limitations ..................................................................................................................................B-2
Design Features............................................................................................................................................B-3
Case Front Controls.......................................................................................................................................B-3
Case Back Controls.......................................................................................................................................B-4
Common Welding Procedures .........................................................................................................B-5 thru B-7
________________________________________________________________________________ ................
Accessories .....................................................................................................Section C
Kits, Options / Accessories...........................................................................................................C-1
Field Installed Options..................................................................................................................C-1
Stick Operations ..........................................................................................................................C-1
________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions........................................................................................................................................D-1
Routine Maintenance ....................................................................................................................................D-1
Periodic Maintenance ...................................................................................................................................D-1
Calibration Specification ...............................................................................................................................D-1
________________________________________________________________________________
Troubleshooting ..............................................................................................Section E
Safety Precautions .......................................................................................................................E-1
How to Use Troubleshooting Guide ...............................................................................................E-1
Using Status LED, Error Fault Codes and Input Control Board .................................................................E-2, E-4
Troubleshooting Guide....................................................................................................E-5 thru E-8
________________________________________________________________________________
Wiring Diagram and Dimension Print ............................................................Section F

________________________________________________________________________
Parts List ................................................................................parts.lincolnelectric.com
Content/details may be changed or updated without notice. For most current Instruction Manuals, go to
parts.lincolnelectric.com.
_______________________________________________________________________________
7
POWER WAVE® R500 INSTALLATION
TECHNICAL SPECIFICATIONS - POWER WAVE R500 ®
POWER SOURCE-INPUT VOLTAGE AND CURRENT

Model Duty Cycle Input Voltage ± 10% Input Amperes Idle Power Power Factor @
Rated Output
40% rating
208/230/400*460/575 80/73/41/37/29
K3169-1 50/60 Hz 500 Watts Max. .95
100% rating (includes 380V to 415V) (fan on)
60/54/30/27/21
RATED OUTPUT
INPUT GMAW SMAW GTAW-DC
VOLTAGE/PHASE/
40% 60% 100% 40% 60% 100% 40% 60% 100%
FREQUENCY
200-208/3/50/60
230/3/50/60 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps 550 Amps 500 Amps 450 Amps
380-415/3/50/60 41.5 Volts 39 Volts 36.5 Volts 42 Volts 40 Volts 38 Volts 32 Volts 30 Volts 28 Volts
460/3/50/60
575/3/50/60
RECOMMENDED INPUT WIRE AND FUSE SIZES 1
INPUT MAXIMUM INPUT CORD SIZE 3 TIME DELAY FUSE

VOLTAGE / PHASE/ AMPERE RATING AND AWG SIZES OR BREAKER 2
FREQUENCY DUTY CYCLE (mm2) AMPERAGE
200-208/3/50/60 80A, 40% 4 (21) 100

230/3/50/60 73A, 40% 4 (21) 90
380-415/3/50/60 41A, 40% 8 (10) 60
460/3/50/60 37A, 40% 8 (10) 45
575/3/50/60 29A, 40% 10 (7) 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 at effective current rating of unit.
A-1
WELDING PROCESS
PROCESS OUTPUT RANGE (AMPERES) OCV (Uo)
Mean Peak
GMAW
GMAW-Pulse 40-550A 60V
FCAW 100V
GTAW-DC 5-550A 24V
PHYSICAL DIMENSIONS
MODEL HEIGHT WIDTH DEPTH WEIGHT
K3169-1 22.45 in ( 570 mm) 14.00in ( 356 mm) 24.80in ( 630mm) 150 lbs (68 kg)*
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
Environmentally Hardened: -4°F to 104°F (-20C to 40C) Environmentally Hardened: -40°F to 185°F (-40C to 85C)
IP23 155º(F) Insulation Class
* Weight does not include input cord.
A-2
SAFETY PRECAUTIONS Read this entire INPUT AND GROUND CONNECTIONS

installation section before you start installation. Only a qualified electrician should connect the POWER WAVE®
R500. Installation should be made in accordance with the
WARNING appropriate National Electrical Code, all local codes and the
information in this manual.
ELECTRIC SHOCK can kill.
• Only qualified personnel should
WARNING
perform this installation. • Lift only with equipment of ade-
• Turn the input power OFF at the quate lifting capacity.
disconnect switch or fuse box • Be sure machine is stable when
before working on this equipment. Turn off the lifting.
input power to any other equipment connected to
• Do not operate machine while
the welding system at the disconnect switch or suspended when lifting.
fuse box before working on the equipment.
• Do not touch electrically hot parts. FALLING
• Always connect the POWER WAVE ® R500 EQUIPMENT can
grounding lug to a proper safety (Earth) ground. cause injury.
------------------------------------------------------------- -------------------------------------------------------------
SELECT SUITABLE LOCATION
The POWER WAVE® R500 will operate in harsh environments.
Even so, it is important that simple preventative measures are MACHINE GROUNDING
followed in order to assure long life and reliable operation. The frame of the welder must be grounded. A ground terminal
marked with a ground symbol is located next to the input power
• The machine must be located where there is free circulation connection block.
of clean air such that air movement in the back, out the sides
and bottom will not be restricted. See your local and national electrical codes for proper grounding
methods.
• Dirt and dust that can be drawn into the machine should be
kept to a minimum. The use of air filters on the air intake is
not recommended because normal air flow may be restricted. HIGH FREQUENCY PROTECTION
Failure to observe these precautions can result in excessive
operating temperatures and nuisance shutdown. Locate the POWER WAVE® R500 away from radio controlled
machinery. The normal operation of the POWER WAVE® R500
• Keep machine dry. Shelter from rain and snow. Do not place may adversely affect the operation of RF controlled equipment,
on wet ground or in puddles.
which may result in bodily injury or damage to the equipment.
• Do not mount the POWER WAVE® R500 over combustible surfaces.
Where there is a combustible surface directly under stationary or
fixed electrical equipment, that surface shall be covered with a
steel plate at least .060” (1.6mm) thick, which shall extend not
less than 5.90” (150mm) beyond the equipment on all sides.
LIFTING
Both handles should be used when lifting POWER WAVE® R500.
When using a crane or overhead device a lifting strap should be
connected to both handles. Do not attempt to lift the POWER
WAVE® R500 with accessories attached to it.
STACKING
The POWER WAVE® R500 cannot be stacked.
TILTING
Place the machine directly on a secure, level surface or on a rec-
ommended undercarriage. The machine may topple over if this
procedure is not followed.
A-3
INPUT FUSE AND SUPPLY WIRE

WARNING CONSIDERATIONS
Only a qualified electrician should
connect the input leads to the Refer to Specification Section for recommended fuse, wire sizes
POWER WAVE® R500. Connections and type of the copper wires. Fuse the input circuit with the rec-
should be made in accordance with ommended super lag fuse or delay type breakers (also called
all local and national electrical "inverse time" or "thermal/magnetic" circuit breakers). Choose
codes and the connection dia- input and grounding wire size according to local or national elec-
grams. Failure to do so may result in bodily injury trical codes. Using input wire sizes, fuses or circuit breakers
or death. smaller than recommended may result in "nuisance" shut-offs
from welder inrush currents, even if the machine is not being
-------------------------------------------------------------
used at high currents.
INPUT CONNECTION
(See Figure A.1)
INPUT VOLTAGE SELECTION
Use a three-phrase supply line. A 1.40 inch diameter access hole
with strain relief is located on the case back. Route input power The POWER WAVE® R500 automatically adjusts to work with dif-
cable through this hole and connect L1, L2, L3 and ground per ferent input voltages. No reconnect switch settings are required.
connection diagrams and National Electric Code. To access the
input power connection block, remove three screws holding the
access door to the side of the machine. WARNING
The POWER WAVE® R500 ON/OFF
switch is not intended as a service
ALWAYS CONNECT THE POWER WAVE GROUNDING LUG
disconnect for this equipment. Only
(LOCATED AS SHOWN IN FIGURE A.1) TO A PROPER SAFETY
a qualified electrician should con-
(EARTH) GROUND.
nect the input leads to the POWER
WAVE® R500. Connections should
be made in accordance with all local and national
electrical codes and the connection diagram
located on the inside of the reconnect access
door of the machine. Failure to do so may result
in bodily injury or death.
-------------------------------------------------------------
FIGURE A.1
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
A-4
GMAW (MIG) WELDING
An arclink compatible wire feeder is recommended for Mig weld-

ing. Refer to Figure A.3 for the connection details.
FIGURE A.3
REGULATOR MIG PROCESS

FLOW METER
GAS HOSE
ARC
RCLLINK CABLE
K1543-[XX] TO NEGATIVE (-) STUD
W ORK CLAMP
TO POSITIVE (+) STUD

W ORK PIECE
PF10
10--M
W IRE F
FEE
EEDDER
A-5
RECOMMENDED WORK CABLE General Guidelines
SIZES FOR ARC WELDING • Select the appropriate size cables per the
“Output Cable Guidelines” below. Excessive voltage
Connect the electrode and work cables between the appropriate drops caused by undersized welding cables and poor connec-
output studs of the POWER WAVE® R500 per the following guide- tions often result in unsatisfactory welding performance.
lines: Always use the largest welding cables (electrode and work)
that are practical, and be sure all connections are clean and
• Most welding applications run with the electrode being positive tight.
(+). For those applications, connect the electrode cable
between the wire drive feed plate and the positive (+) output Note: Excessive heat in the weld circuit indicates undersized
stud on the power source. Connect a work lead from the nega- cables and/or bad connections.
tive (-) power source output stud to the work piece
• When negative electrode polarity is required, such as in some • Route all cables directly to the work and wire
Innershield applications, reverse the output connections at the feeder, avoid excessive lengths and do not coil
power source (electrode cable to the negative (-) stud, and excess cable. Route the electrode and work cables in close
work cable to the positive (+) stud). proximity to one another to minimize the loop area and there-
fore the inductance of the weld circuit.
CAUTION
• Always weld in a direction away from the work
Negative electrode polarity operation WITHOUT (ground) connection.
use of a remote work sense lead (21) requires the
Negative Electrode Polarity attribute to be set. Table A.1 shows copper cable sizes recommended for different
See the Remote Sense Lead Specification section currents and duty cycles. Lengths stipulated are the distance
of this document for further details. from the welder to work and back to the welder again. Cable
------------------------------------------------------------- sizes are increased for greater lengths primarily for the purpose
For additional Safety information regarding the electrode and of minimizing cable drop.
work cable set-up, See the standard “SAFETY INFORMA-
TION” located in the front of this Instruction Manual.
OUTPUT CABLE GUIDELINES (Table A.1)

Percent Duty CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED
Amperes Cycle 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).
A-6
CABLE INDUCTANCE AND ITS age sense leads are used to improve the accuracy of the arc volt-
age information supplied to the control pc board. Sense Lead Kits
EFFECTS ON WELDING (K940-xx) are available for this purpose.
Excessive cable inductance will cause the welding performance The POWER WAVE® R500 has the ability to automatically sense
to degrade. There are several factors that contribute to the over- when remote sense leads are connected. With this feature there
all inductance of the cabling system including cable size, and are no requirements for setting-up the machine to use remote
sense leads. This feature can be disabled through the Weld
loop area. The loop area is defined by the separation distance
Manager Utility (available at
between the electrode and work cables, and the overall welding www.powerwavesoftware.com) or through the set up
loop length. The welding loop length is defined as the total of menu (if a user interface is installed into the power source).
length of the electrode cable (A) + work cable (B) + work path
(C) (See Figure A.5). CAUTION
To minimize inductance always use the appropriate size cables, If the auto sense lead feature is disabled and
and whenever possible, run the electrode and work cables in remote voltage sensing is enabled but the sense
close proximity to one another to minimize the loop area. Since leads are missing or improperly connected
the most significant factor in cable inductance is the welding extremely high welding outputs may occur.
loop length, avoid excessive lengths and do not coil excess -------------------------------------------------------------
cable. For long work piece lengths, a sliding ground should be General Guidelines for Voltage Sense Leads
considered to keep the total welding loop length as short as pos- Sense leads should be attached as close to the weld as practical,
sible. and out of the weld current path when possible. In extremely sen-
sitive applications it may be necessary to route cables that con-
REMOTE SENSE LEAD tain the sense leads away from the electrode and work welding
SPECIFICATIONS cables.
Voltage sense leads requirements are based on the weld process

Voltage Sensing Overview
(See Table A.2)
The best arc performance occurs when the POWER WAVE® R500
has accurate data about the arc conditions.
Depending upon the process, inductance within the electrode and
work cables can influence the voltage apparent at the studs of the
welder, and have a dramatic effect on performance. Remote volt-
TABLE A.2
Process Electrode Voltage Sensing (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
(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
R500 A
WORK
B
A-7
Electrode Voltage Sensing
The remote ELECTRODE sense lead (67) is built into the 5-pin
arclink control cable and is always connected to the wire drive
feed plate when a wire feeder is present. Enabling or disabling
electrode voltage sensing is application specific, and automati-
cally configured by the active weld mode.
CAUTION
If the auto sense lead feature is disabled and the
weld polarity attribute is improperly configured
extremely high welding outputs may occur.
-------------------------------------------------------------
Work Voltage Sensing
While most applications perform adequately by sensing the work

voltage directly at the output stud, the use of a remote work volt-
age sense lead is recommended for optimal performance. The
remote WORK sense lead (21) can be accessed through the four-
pin voltage sense connector located on the control panel by
using the K940 Sense Lead Kit. It must be attached to the work
as close to the weld as practical, but out of the weld current
path. For more information regarding the placement of remote
work voltage sense leads, see in this section entitled "Voltage
Sensing Considerations for Multiple Arc Systems."
Negative Electrode Polarity

The POWER WAVE® R500 has the ability to automatically sense
the polarity of the sense leads. With this feature there are no
set-up requirements for welding with negative electrode polarity.
This feature can be disabled through the Weld Manager Utility
(available at www.powerwavesoftware.com) or through the set
up menu (if a user interface is installed into the power source).
A-8
VOLTAGE SENSING If Sense Leads ARE Used:

CONSIDERATIONS FOR MULTIPLE
• Position the sense leads out of the path of the weld current.
ARC SYSTEMS Especially any current paths common to adjacent arcs.
Current from adjacent arcs can induce voltage into each oth-
Special care must be taken when more than one arc is welding ers current paths that can be misinterpreted by the power
simultaneously on a single part. Multiple arc applications do not sources, and result in arc interference.
necessarily dictate the use of remote work voltage sense leads,
but they are strongly recommended. • For longitudinal applications, connect all work leads at one
end of the weldment, and all of the work voltage sense leads
If Sense Leads ARE NOT Used: at the opposite end of the weldment. Perform welding in the
direction away from the work leads and toward the sense
• Avoid common current paths. Current from adjacent arcs can leads.
induce voltage into each others current paths that can be (See Figure A.6)
misinterpreted by the power sources, and result in arc inter-
ference.
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.
A-9
• For circumferential applications, connect all work
leads on one side of the weld joint, and all of the work volt-
age 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
A-10
CONTROL CABLE CONNECTIONS Connection Between Power Source and Ethernet

Networks
General Guidelines
The POWER WAVE® R500 is equipped with an IP67 rated ODVA
Genuine Lincoln control cables should be used at all times compliant RJ-45 Ethernet connector, which is located on the rear
(except where noted otherwise). Lincoln cables are specifically panel. All external Ethernet equipment (cables, switches, etc.),
designed for the communication and power needs of the Power as defined by the connection diagrams, must be supplied by the
Wave® / Power Feed™ systems. Most are designed to be con- customer. It is critical that all Ethernet cables external to either a
nected end to end for ease of extension. Generally, it is recom- conduit or an enclosure are solid conductor, shielded cat 5e
mended that the total length not exceed 100ft. (30.5m). The use cable, with a drain. The drain should be grounded at the source
of non-standard cables, especially in lengths greater than 25 of transmission. For best results, route Ethernet cables away
feet, can lead to communication problems (system shutdowns), from weld cables, wire drive control cables, or any other current
poor motor acceleration (poor arc starting), and low wire driving carrying device that can create a fluctuating magnetic field. For
force (wire feeding problems). Always use the shortest length of additional guidelines refer to ISO/IEC 11801. Failure to follow
control cable possible, and DO NOT coil excess cable. these recommendations can result in an Ethernet connection
failure during welding.
Regarding cable placement, best results will be obtained when
control cables are routed separate from the weld cables. This
minimizes the possibility of interference between the high cur-
rents flowing through the weld cables, and the low level signals
in the control cables. These recommendations apply to all com-
munication cables including ArcLink® and Ethernet connections.
Product specific Installation Instructions
Connection Between Power Source and ArcLink® Compatible

Wirefeeders (K1543, K2683 – ArcLink Control Cable)
The 5-pin ArcLink control cable connects the power source to

the wire feeder. The control cable consists of two power leads,
one twisted pair for digital communication, and one lead for volt-
age sensing. The 5-pin ArcLink connection on the Power Wave®
R500 is located on the rear panel (See Case Back Controls in the
Operation Section). The control cable is keyed and polar-
ized to prevent improper connection. Best results will be
obtained when control cables are routed separate from the weld
cables, especially in long distance applications. The recom-
mended combined length of the ArcLink control cable network
should not exceed 200ft. (61.0m).
A-11
POWER WAVE® R500 OPERATION
SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON

READ AND UNDERSTAND ENTIRE SECTION THIS MACHINE OR IN THIS MANUAL
BEFORE OPERATING MACHINE.
WARNING WARNING OR
CAUTION
• ELECTRIC SHOCK CAN KILL.
• Do not touch electrically live
part or electrode with skin or DANGEROUS
wet clothing.
• Insulate yourself from work and VOLTAGE
ground.
• Always wear dry insulating gloves.
• Do not operate with covers, panels or guards POSITIVE OUTPUT
removed or open.
-----------------------------------------------------------
• FUMES AND GASSES can be
dangerous.
NEGATIVE OUTPUT
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing HIGH TEMPERA-
zone. TURE
------------------------------------------
• WELDING SPARKS can cause

STATUS
fire or explosion.
• Keep flammable material away.
----------------------------------------- PROTECTIVE
ARC RAYS can burn. GROUND
• Wear eye, ear and body protec-
tion.
----------------------------------------------------------- COOLER
SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN-
UAL. OUTPUT
-----------------------------------------------------------
POWER-UP SEQUENCE OPERATORS

MANUAL
When the POWER WAVE® R500 is powered up, it can take as
long as 30 seconds for the machine to be ready to weld. During
this time period the user interface will not be active. WORK
DUTY CYCLE
The duty cycle is based on a ten-minute period. A 40% duty

CIRCUIT BREAKER
cycle represents 4 minutes of welding and 6 minutes of idling in
a ten-minute period. Refer to the technical specification section
for the POWER WAVE® R500’s duty cycle ratings.
B-1
PRODUCT DESCRIPTION PROCESS LIMITATIONS
PRODUCT SUMMARY The software based weld tables of the POWER WAVE® R500 limit
The POWER WAVE® R500 is a portable multi-process power the process capability within the output range and the safe limits
source with high-end functionality capable of Stick, DC TIG, MIG, of the machine. In general the processes will be limited to .030-
Pulsed MIG and Flux-Cored welding. It is ideal for a wide variety .052 solid steel wire, .030 -.045 stainless wire, .035 -1/16 cored
of materials including aluminum, stainless, and nickel — where wire, and .035 - 1/16 Aluminum wire.
arc performance is critical.
EQUIPMENT LIMITATIONS
The POWER WAVE® R500 is designed to be a very flexible weld-
ing system. Like existing Power Wave’s®, the software based Only ArcLink compatible semiautomatic wire feeders and users
architecture allows for future upgradeability. One significant interfaces may be used. If other Lincoln wire feeders or non-
change from the current range of Power Wave® units is that the Lincoln wire feeders are used there will be limited process capa-
Ethernet communication feature is standard on the POWER bility and performance and features will be limited.
WAVE® R500 which allows for effortless software upgrades
through Powerwavesoftware.com. The Ethernet communication
also gives the POWER WAVE® R500 the ability to run Production
Monitoring™ 2. A Devicenet option allows the POWER WAVE®
R500 to be used in a wide range of configurations and the
POWER WAVE ® R500 is designed to be compatible with
advanced welding modules like STT.
RECOMMENDED PROCESSES AND

EQUIPMENT
The POWER WAVE® R500 is recommended for semiautomatic welding,
and may also be suitable for basic hard automation applications. The
POWER WAVE® R500 can be set up in a number of configurations, some
requiring optional equipment or welding programs.
RECOMMENDED EQUIPMENT
The POWER WAVE® R500 is recommended for robotic and semiauto-

matic welding. The POWER WAVE® R500 can be set up in a number of
configurations, some requiring optional equipment or welding programs.
RECOMMENDED PROCESSES
The POWER WAVE® R500 is a high speed, multi-process power

source capable of regulating the current, voltage, or power of the
welding arc. With an output range of 5 to 550 amperes, it sup-
ports a number of standard processes including synergic GMAW,
GMAW-P, FCAW, FCAW-SS, SMAW, GTAW and GTAW-P on vari-
ous materials especially steel, aluminum and stainless.
B-2
DESIGN FEATURES 3. FEEDER STATUS LED - A two color LED that indicates
system errors. The Power Wave R500 is equipped with two
Loaded with Standard Features indicators. One is for the inverter power source, while the
other indicates the status of the feeder control system.
• Multiple process DC output range: 5 - 550 Amps Normal operation is a steady green light. For more informa-
tion and a detailed listing, see the troubleshooting section of
• 200 – 600 VAC, 3 phase, 50-60Hz input power this document or the Service Manual for this machine. (See
Troubleshooting Section for operational func-
• New and Improved Line Voltage Compensation holds the out- tions.)
put constant over wide input voltage fluctuations.
NOTE: The Power Wave R500 status light will flash green, and
• Utilizes next generation microprocessor control, based on the sometimes red and green, for up to one minute when the
ArcLink® platform. machine is first turned on. This is a normal situation as the
machine goes through a self test at power up.
• State of the art power electronics technology yields superior
welding capability. 4. POWER SWITCH - Controls power to the POWER WAVE®
R500.
• Electronic over current protection
5. NEGATIVE WELD OUTPUT
• Input over voltage protection.
6. POSITIVE WELD OUTPUT
• F.A.N. (fan as needed). Cooling fan only runs when needed.
7. VOLTAGE SENSE CONNECTOR: Allows for sepa-
• Thermostatically protected for safety and reliability. rate remote electrode and work sense leads.
• Ethernet connectivity.
Pin Lead Function
• Panel mounted Status and Thermal LED indicators facilitate 3 21 Work Voltage Sense
quick and easy troubleshooting. 1 67E Electrode Voltage Sense
• Potted PC boards for enhanced ruggedness/reliability.
• Enclosure reinforced with heavy duty aluminum extrusions for FIGURE B.1
mechanical toughness
• Waveform Control Technology™ for good weld appearance

and low spatter, even when welding nickel alloys.
1
• Sync Tandem installed.
CASE FRONT CONTROLS

2
(See Figure B.1)
1. STATUS LED - (See Troubleshooting Section for opera-

tional functions). 3
2. THERMAL LED - Indicates when machine has thermal 4
fault.
5 6 7
B-3
CASE BACK CONTROLS 9. EXTERNAL I/O CONNECTOR:

(See Figure B.2) Terminal Strip for making simple input signal connections.
(See Figure B.2A)
1. 115 VAC CIRCUIT BREAKER The terminal strip is divided into three groups:
Group #1 - TRIGGER
2. 115 VAC RECEPTACLES Group #2 - FEED FORWARD/REVERSE
Group #3 - SHUTDOWN INPUTS
3. WIRE FEEDER RECEPTACLE (14 PIN):
Robotic wire feeder connector (for 4R220, Power Feed 10 All inputs use "normally open" logic except the shutdown group.
Robotic, etc). The shutdown inputs use "normally closed" logic, and are
always enabled. Unused shutdowns must be tied to the +15V
4. DIFFERENTIAL I/O CONNECTOR: supply for the shutdown group. Machines are shipped from the
For (Optional) K2902-1 STT or K2912-1 Advanced Module. factory with jumpers installed on both shutdown inputs.
5. ARCLINK OUTPUT CONNECTOR (5 PIN):

Provides power and communication to ArcLink
periferals (semi-automatic feeder, Cool Arc 55S, etc). FIGURE B.2A
+15VDC - Group #1
+15VDC - Group #3
+15VDC - Group #2
6. DEVICENET KIT (OPTIONAL):
Shutdown 1 Input
Shutdown 2 Input
For PLC control.
Dual Procedure
Feed Reverse
Feed Forward
7. 40V CIRCUIT BREAKER
Gas Purge
2/4 Step
Trigger
8. ETHERNET (SHIELDED):
For ArcLink XT enabled robot, computer or network connec-
tion.
12 11 10 9 8 7 6 5 4 3 2 1
FIGURE B.2
1
8
2
B-4
COMMON WELDING PROCEDURES BASIC WELDING CONTROLS
WARNING Weld Mode

Selecting a weld mode determines the output characteristics of
MAKING A WELD the Power Wave® power source. Weld modes are developed
The serviceability of a product or structure utiliz- with a specific electrode material, electrode size, and shielding
ing the welding programs is and must be the gas. For a more complete description of the weld modes pro-
sole responsibility of the builder/user. Many grammed into the POWER WAVE® R500 at the factory, refer to
variables beyond the control of The Lincoln the Weld Set Reference Guide supplied with the machine or
Electric Company affect the results obtained in available at www.powerwavesoftware.com.
applying these programs. These variables
include, but are not limited to, welding proce- Wire Feed Speed (WFS)
dure, plate chemistry and temperature, weld- In synergic welding modes (synergic CV, GMAW-P), WFS is the
ment design, fabrication methods and service dominant control parameter. The user adjusts WFS according to
requirements. The available range of a welding factors such as wire size, penetration requirements, heat input,
program may not be suitable for all applications, etc. The POWER WAVE® R500 then uses the WFS setting to
and the build/user is and must be solely respon- adjust the voltage and current according to settings contained in
sible for welding program selection. the POWER WAVE®.
Choose the electrode material, electrode size, shielding gas, and In non-synergic modes, the WFS control behaves like a conven-
process (GMAW, GMAW-P etc.) appropriate for the material to be tional power source where WFS and voltage are independent
welded. adjustments. Therefore, to maintain proper arc characteristics,
the operator must adjust the voltage to compensate for any
Select the weld mode that best matches the desired welding changes made to the WFS.
process. The standard weld set shipped with the POWER WAVE®
R500 encompasses a wide range of common processes that will Amps
meet most needs. If a special weld mode is desired, contact the In constant current modes, this control adjusts the welding
local Lincoln Electric sales representative. amperage.
All adjustments are made through the user interface. Because of Volts
the different configuration options your system may not have all In constant voltage modes, this control adjusts the welding volt-
of the following adjustments. age.
See Accessories Section for Kits and Options avaliable to use
with the POWER WAVE® R500. Trim
In pulse synergic welding modes, the Trim setting adjusts the arc
DEFINITION OF WELDING MODES length. Trim is adjustable from 0.50 to 1.50. 1.00 is the nomi-
nal setting and is a good starting point for most conditions.
NON-SYNERGIC WELDING MODES
• A Non-synergic welding mode requires all welding UltimArc™ Control
process variables to be set by the operator. UltimArc™ Control allows the operator to vary the arc character-
istics. UltimArc™ Control is adjustable from –10.0 to +10.0
SYNERGIC WELDING MODES with a nominal setting of 0.0.
• A Synergic welding mode offers the simplicity of single
knob control. The machine will select the correct voltage and
amperage based on the Wire Feed Speed (WFS) set by the
operator.
B-5
SMAW (STICK) WELDING Non Synergic CV

The welding current and Arc Force settings can be set through a In non-synergic modes, the WFS control behaves more like a
Power Feed ™ 10M or Power Feed ™ 25M wire feeder. conventional CV power source where WFS and voltage are inde-
Alternatively an optional Stick / TIG UI can be installed into the pendent adjustments. Therefore to maintain the arc characteris-
power source to control these settings locally. tics, the operator must adjust the voltage to compensate for any
changes made to the WFS.
In a SMAW (STICK mode), Arc Force can be adjusted. It can be
set to the lower range for a soft and less penetrating arc charac- All CV Modes
teristic (negative numeric values) or to the higher range (positive Pinch adjusts the apparent inductance of the wave shape. The
numeric values) for a crisp and more penetrating arc. Normally, “pinch” function is inversely proportional to inductance.
when welding with cellulosic types of electrodes (E6010, E7010, Therefore, increasing Pinch Control greater than 0.0 results in a
E6011), a higher energy arc is required to maintain arc stability. crisper arc (more spatter) while decreasing the Pinch Control to
This is usually indicated when the electrode sticks to the work- less than 0.0 provides a softer arc (less spatter).
piece or when the arc becomes unstable during manipulative
technique. For low hydrogen types of electrodes (E7018, E8018, PULSE WELDING
E9018, etc.) a softer arc is usually desirable and the lower end of Pulse welding procedures are set by controlling an overall “arc
the Arc Control suits these types of electrodes. In either case the length” variable. When pulse welding, the arc voltage is highly
arc control is available to increase or decrease the energy level dependent upon the waveform. The peak current, back ground
delivered to the arc. current, rise time, fall time and pulse frequency all affect the
voltage. The exact voltage for a given wire feed speed can only
GTAW (TIG) WELDING be predicted when all the pulsing waveform parameters are
The welding current can be set through a Power Feed™ 10M or known. Voltage or Trim can be adjusted.
Power Feed™ 25M wire feeder. Alternatively an optional Stick /
TIG UI can be installed into the power source to control these Trim adjusts the arc length and ranges from 0.50 to 1.50 with a
settings locally. nominal value of 1.00. Trim values greater than 1.00 increase
the arc length, while values less than 1.00 decrease the arc
The TIG mode features continuous control from 5 to 550 amps length. (See figure B.3)
with the use of an optional foot amptrol. The POWER WAVE®
R500 can be run in either a Touch Start TIG mode or Scratch
start TIG mode.
CONSTANT VOLTAGE WELDING

Synergic CV
For each wire feed speed, a corresponding voltage is prepro-
grammed into the machine through special software at the fac-
tory.
The nominal preprogrammed voltage is the best average voltage
for a given wire feed speed, but may be adjusted to preference.
When the wire feed speed changes, the POWER WAVE® R500
automatically adjusts the voltage level correspondingly to main-
tain similar arc characteristics throughout the WFS range.
FIGURE B.3
B-6
Most pulse welding programs are synergic. As the wire feed

speed is adjusted, the POWER WAVE® R500 will automatically
recalculate the waveform parameters to maintain similar arc
properties.
The POWER WAVE® R500 utilizes “adaptive control” to compen-

sate for changes in the electrical stick-out while welding.
(Electrical stick-out is the distance from the contact tip to the
work piece.) The POWER WAVE® R500 waveforms are optimized
for a 0.75” stick-out. The adaptive behavior supports a range of
stick-outs from 0.50 to 1.25”. At very low or high wire feed
speeds, the adaptive range may be less due to reaching physical
limitations of the welding process.
UltimArc™ Control adjusts the focus or shape of the arc.

UltimArc™ Control is adjustable from -10.0 to +10.0 with a
nominal setting of 0.0. Increasing the UltimArc™ Control
increases the pulse frequency and background current while
decreasing the peak current. This results in a tight, stiff arc
used for high speed sheet metal welding. Decreasing the
UltimArc™ Control decreases the pulse frequency and 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
B-7
POWER WAVE® R500 ACCESSORIES
KITS, OPTIONS AND ACCESSORIES

All Kits Options and Accessories are found on the Web site: AWG #1 Coaxial Cables:
(www.lincolnelectric.com) Order K2593-25 for 25 feet (7.6 m) cable length.
Order K2593-50 for 50 feet (15.2 m) cable length.
Order K2593-100 for 100 feet (30.5 m) cable
FACTORY INSTALLED length.
None Available
Welding Fume Extractors
FIELD INSTALLED OPTIONS Lincoln offers a wide range of fume extraction environmental
system solutions, ranging from portable systems easily wheeled
GENERAL OPTIONS around a shop to shop-wide central systems servicing many
dedicated welding stations.
DeviceNet Kit Request Lincoln publication E13.40
Mounts inside the back of the POWER WAVE® R500. Allows (See www.lincolnelectric.com)
Devicenet objects to communicate with the POWER WAVE ®
R500.
Order K2827-1
Work Voltage Sense Lead Kit

Required to accurately monitor voltage at the arc.
Order K940-XX Series
Order K1811-XX Series
Deluxe Adjustable Gas Regulator & Hose Kit

Accommodates CO 2 , Argon, or Argon-blend gas cylinders.
Includes a cylinder pressure gauge, dual scale flow gauge and
4.3 ft. (1.3 m) gas hose.
Order K586-1
K2149-1 Work Lead Package
K1842-10 10ft. Weld Power Cable
Coaxial Welding Cable

Optimum weld cables for minimizing cable inductance and opti-
mizing welding performance.
AWG 1/0 Coaxial Cables:

Order K1796-100 for 100 feet (30.5 m) cable
length.
C-1
POWER WAVE® R500 MAINTENANCE
SAFETY PRECAUTIONS
WARNING
•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 accumulat-
ed dust and dirt from the intake and outlet louvers, and the cool-
ing channels in the machine.
PERIODIC MAINTENANCE
Calibration of the POWER WAVE® R500 is critical to its operation.
Generally speaking the calibration will not need adjustment.
However, neglected or improperly calibrated machines may not
yield satisfactory weld performance. To ensure optimal perfor-
mance, the calibration of output Voltage and Current should be
checked yearly.
CALIBRATION SPECIFICATION
Output Voltage and Current are calibrated at the factory.
Generally the machine calibration will not need adjustment.
However, if the weld performance changes, or the yearly calibra-
tion check reveals a problem, use the calibration section of the
Diagnostics Utility to make the appropriate adjustments.
The calibration procedure itself requires the use of a grid, and

certified actual meters for voltage and current. The accuracy of
the calibration will be directly affected by the accuracy of the
measuring equipment you use. The Diagnostics Utility
includes detailed instructions, and is available on the Service
Navigator CD or at www.powerwavesoftware.com.
D-1
POWER WAVE® R500 TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs per-
formed 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 through-
out this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you locate and This column provides a course of action for the Possible Cause,
repair possible machine malfunctions. Simply follow the three- generally it states to contact your local Lincoln Authorized Field
step procedure listed below. Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM). If you do not understand or are unable to perform the
Look under the column labeled “PROBLEM (SYMPTOMS)”. This Recommended Course of Action safely, contact your local
column describes possible symptoms that the machine may Lincoln Authorized Field Service Facility.
exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.
Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symp-
tom.
Step 3. RECOMMENDED COURSE OF ACTION
WARNING
• Turn the input power OFF at the welding power source before installation or changing
drive rolls and/or guides.
• Do not touch electrically live parts.
• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and
ground and could remain energized several seconds after the gun trigger is released.
• Welding power source must be connected to system ground per the National Electrical Code or any
applicable local codes.
• Only qualified personnel should perform maintenance work.
--------------------------------------------------------------------------------------------------------------------------------
Observe all additional Safety Guidelines detailed throughout this manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-1
USING THE STATUS LED TO basic troubleshooting charts for both machine and weld performance.
TROUBLESHOOT SYSTEM PROBLEMS The status light for the main control board and input control board are
dual-color LED’s. Normal operation for each is steady green.
Not all of the POWER WAVE® R500 errors will be displayed on the user
interface (if it is installed). There are two status lights that display error Error conditions are indicated in the following chart Table E.1.
codes. If a problem occurs it is important to note the condition of the
status lights. Therefore, prior to cycling power to the sys-
tem, check the power source status light for error
sequences as noted below.
There is one externally mounted status light located on the case front of
the machine. This status light corresponds to the main control board
and input control board’s status.
Included in this section is information about the Status Lights and some
TABLE E.1
Light Meaning
Condition Main control board status light and Input control board
Steady Green System OK. Power source is operational, and is communicating normally with all healthy peripheral equipment connected to its
ArcLink network.
Blinking Green
Occurs during power up or a system reset, and indicates the POWER WAVE® R500 is mapping (identifying) each component in
the system. Normal for first 1-10 seconds after power is turned on, or if the system configuration is changed during operation.
Indicates Auto-mapping has failed

Fast Blinking Green
Alternating Green and Red Non-recoverable system fault. If the Status lights are flashing any combination of red and green, errors are present. Read the
error code(s) before the machine is turned off.
Error Code interpretation through the Status light is detailed in the Service Manual. Individual code digits are flashed in
red with a long pause between digits. If more than one code is present, the codes will be separated by a green light. Only active
error conditions will be accessible through the Status Light.
Error codes can also be retrieved with the Power Wave Manager Utility available at
www.powerwavesoftware.com). This is the preferred method, since it can access historical information contained in the
error logs.
To clear the active error(s), turn power source off, and back on to reset.
Steady Red Not applicable.
Blinking Red Not applicable.
Status LED off Not applicable.
CAUTION
E-2
Observe all Safety Guidelines detailed throughout this manual
ERROR CODES FOR THE POWER WAVE® R500

The following is a partial list of possible error codes for the POWER WAVE® R500. For a complete listing consult the Service Manual for
this machine.
MAIN CONTROL BOARD ( “STATUS” LIGHT)

Error Code # Indication
36 Thermal error Indicates over temperature. Usually accompanied by Thermal LED. Check fan
operation. Be sure process does not exceed duty cycle limit of the machine
The long term average secondary (weld) current limit has been exceeded.
54 Secondary (Output) over current error
NOTE: The long term average secondary current limit is 325A (1 Phase) or
575A (3 Phase).
56 Chopper communication error Indicates communication link between main control board and chopper has
errors. If cycling the input power on the machine does not clear the error, contact
the Service Department.
58 Primary Fault error Review error code from input board status light or status beeper. Most likely
caused by an over power condition which caused an under voltage on the prima-
ry bus. If cycling the input power on the machine does not clear the error, contact
the Service Department.
71 Secondary (Output) over power error The long term secondary (Weld) power limit has been exceeded.
NOTE: The long term average secondary current limit is 25kw (3 Phase), 14kw (1
Phase).
Other Error codes that contain three or four digits are defined as fatal errors. These
codes generally indicate internal errors on the Power Source Control Board. If
cycling the input power on the machine does not clear the error, contact the
Service Department.
CAUTION
E-3
INPUT CONTROL BOARD

Error Code # Indication Type
Instantaneous input current limit has been exceeded. Typically indicates short
331 Instantaneous Input Current Limit term power overload. If problem persists contact Service Department. Persistent
Input current limit was exceeded during machine power-up. If problem per-
334 Startup Current Check Failure sists contact Service Department. Persistent
Input voltage was too high or too low during machine power-up. Verify that
335 Startup Voltage Check Failure the input voltage is between 200V and 650V. Temporary
Thermostat on primary module tripped. Typically caused by a fan malfunction
336 Thermal Fault or blocked air vent. Temporary
The DC bus voltage was not charged to a certain level at end of precharge. If
337 Precharge Timeout problem persists contact Service Department. Persistent
The input power drawn by the machine exceeded a safe level. If problem per-
338 Input Power Limit sists, contact the Service Department. Persistent
The input voltage momentarily dropped out. Check connections and verify
341 Input Voltage Dropout quality of input power. Temporary
Transformer current too high. Typically indicates short-term power overload. If
346 Transformer Primary Overcurrent problem persists, contact the Serivce Department. Persistent
Average input current limit has been exceeded. Typically indicates short term
347 Average Input Current Limit power overload. If problem persists contact Service Department. Persistent
The DC bus voltage dropped below the allowable limit. If problem persists,
349 Bus Undervoltage contact the Service Department. 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.
WIRE DRIVE MODULE

Error Code # Indication
81 Motor Overload Long term average motor current limit has been exceeded. Typically indicates
mechanical overload of system. If problem continues consider higher torque gear
ratio (lower speed range).
82 Motor Overcurrent Absolute maximum motor current level has been exceeded. This is a short term
average to protect drive circuitry.
83 Shutdown #1 Is Open 1.This refers to the ‘green’ I/O connector on the bottom of the controller.
If not being externally accessed, verify the integrity of the connector and jumper.
If accessed through a remote circuit, verify the integrity of that circuit.
84 Shutdown #2 Is Open 1.This refers to the ‘green’ I/O connector on the bottom of the controller.
If not being externally accessed, verify the integrity of the connector and jumper.
If accessed through a remote circuit, verify the integrity of that circuit.
CAUTION
E-4
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Basic Machine Problems
Input fuses keep blowing 1. Improperly sized input fuses. 1. Make sure fuses are properly sized. See
installation section of this manual for
recommended sizes.
2. Improper Weld Procedure requiring out- 2. Reduce output current, duty cycle, or
put levels in excess of machine rating. both.
3. Major physical or electrical damage is 3. Contact your local authorized Lincoln

evident when the covers are removed. Electric Field Service facility for techni-
cal assistance.
Machine will not power up (no lights) 1. Make sure input supply disconnect has
1. No Input Power been turned ON. Check input fuses.
Make certain that the Power Switch
(SW1) on the power source is in the
“ON” position.
2. Make certain that input voltage is cor-

2. Input voltage is too low or too high.
rect, according to the Rating Plate locat-
ed on the rear of the machine.
Machine won’t weld, can’t get any output. 1. Input voltage is too low or too high. 1. Make certain that input voltage is cor-
rect, according to the Rating Plate locat-
ed on the rear of the machine.
This problem will normally be accompa- 2. Thermal Error. 2. See “Thermal LED is ON” section.
nied by an error code. See “Status Light”
section of this document for additional
3. Secondary current limit has been 3. Possible short in output circuit. If con-
information. exceeded. (see error 54) dition persists, contact an authorized
3a. Input control board fault (see input Lincoln Electric Field Service facility.
control board error status).
CAUTION
E-5
Thermal LED is ON Improper
Basic fan operation
Machine Problems (Continued)
Thermal LED is ON 1. Improper fan operation. 1. Check for proper fan operation. Fan
should run in a low speed setting when
the machine is idle and in a high speed
when the output is triggered. Check for
material blocking intake or exhaust lou-
vers, or for excessive dirt clogging cool-
ing channels in machine.
2. Open thermostat circuit. 2. Check for broken wires, open connec-

tions or faulty thermostats in the ther-
mostat circuit.
“Real Time Clock” no longer functioning 1. Control PC Board Battery. 1. Replace the battery (Type: BS2032)
Weld and Arc Quality Problems

General degradation of weld performance 1. Wire feed problem. 1. Check for feeding problems.
2. Cabling problems. 2. Check for bad connections, excessive

loops in cable, etc.
NOTE: The presence of heat in the exter-

nal welding circuit indicates poor connec-
tions or undersized cables.
3. Loss of, or improper Shielding Gas. 3. Verify gas flow and type are correct.
4. Verify weld mode is correct for process. 4.Select the correct weld mode for the
application.
5. Machine calibration. 5. The power source may require calibra-

tion. (current, voltage, WFS).
CAUTION
E-6
Weld and Arc Quality Problems (Continued)
Wire burns back to tip at the end of the 1. Burnback Time 1. Reduce burnback time and/or work point.
weld.
Machine output shuts down during a weld. 1. Secondary current limit has been exceed- 1. Adjust procedure or reduce load to lower
ed, and the machine shuts down to pro- current draw from the machine.
tect itself.
2. System Fault 2. A non-recoverable fault will interrupt

welding. This condition will also result in
a status light blinking. See the Status
Light section for more information.
Machine won’t produce full output. 1. Input voltage may be too low, limiting 1. Make certain that the input voltage is
output capability of the power source. proper, according to the Rating Plate
located on the rear of the machine.
2. The input may be single phase. 2. Verify all 3 phases are present.
3. Machine calibration. 3. Calibrate secondary current and voltage.
Excessively long and erratic arc. 1. Wire feed problem. 1. Check for feeding problems. Make sure
proper gear ratio has been selected.
2. Loss of, or improper Shielding Gas 2. Verify gas flow and type are correct
3. Machine calibration. 3. Calibrate secondary current and voltage.
CAUTION
E-7
Ethernet
Cannot Connect 1. Physical connection. 1. Verify that the correct patch cable or
cross over cable is being used (refer to
local IT department for assistance).
1a. Verify the cables are fully inserted into

the bulk head connector.
1b. The LED under the PC board ethernet

connector will be lit when the machine
is connected to another network device.
2. IP address information. 2. Use the appropriate PC utility to verify the

correct IP address information has been
entered.
2a. Verify no duplicate the IP addresses

exist on the network.
3. Ethernet Speed 3. Verify that the network device connected

to the Power Wave is either a 10-baseT
device or a 10/100-baseT device.
Connection Drops while welding 1. Cable Location 1. Verify Network cable is not located next
to current carrying conductors. This
would include input power cables and
welding output cables.
CAUTION
E-8
POWER WAVE® R500
F-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure
panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
DIAGRAMS
POWER WAVE® R500
27.43
13.94
F-2
22.45
6.00
18.35
24.76
A.01
DIAGRAMS
L16215
NOTES
F-3
NOTES
F-4
NOTES
F-5
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

l Insulate yourself from work and
ground.
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el
Spanish
AVISO DE bajo carga con la piel o ropa moja-

da.
fuera del área de trabajo. cuerpo.
l Aislese del trabajo y de la tierra.

PRECAUCION
French l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
German l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
WARNUNG l Isolieren Sie sich von den
Elektroden und dem Erdboden!
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
Portuguese
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
l Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
l Los humos fuera de la zona de res- l Desconectar el cable de ali- l No operar con panel abierto o
Spanish
piración.
l Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases. PRECAUCION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux French
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés.
ATTENTION
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen!
WARNUNG
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
Portuguese
l Use ventilação e exhaustão para l Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. l Não opere com os paineis abertos ATENÇÃO
l Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information
or advice create, expand or alter any warranty with respect to the sale
of our products.
Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
TABLE OF CONTENTS
requirements.
INSTALLATION
Subject to Change – This information is accurate to the best of our OPERATION
ACCESSORIES
knowledge at the time of printing. Please refer to MAINTENANCE
TROUBLESHOOTING
www.lincolnelectric.com for any updated information. DIAGRAMS

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Operator’s Manual

POWER WAVE ® R500

Register your machine: Need Help? Call 1.888.935.3877

For Service outside the USA:

Serial: (ex: U1060512345)

IM10133 | Issue Date 01/15

SECTION A: 1.d. Keep all equipment safety guards, covers

2.b. EMF fields may interfere with some pacemakers, and

ELECTRIC SHOCK ARC RAYS CAN BURN.

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

6.j. Do not use a welding power source for pipe thawing.

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

Parts List ................................................................................parts.lincolnelectric.com

TECHNICAL SPECIFICATIONS - POWER WAVE R500 ®

POWER SOURCE-INPUT VOLTAGE AND CURRENT

INPUT MAXIMUM INPUT CORD SIZE 3 TIME DELAY FUSE

200-208/3/50/60 80A, 40% 4 (21) 100

1. Based on U.S. National electrical Code

IP23 155º(F) Insulation Class

* Weight does not include input cord.

SAFETY PRECAUTIONS Read this entire INPUT AND GROUND CONNECTIONS

INPUT FUSE AND SUPPLY WIRE

INPUT CORD STRAIN RELIEF

An arclink compatible wire feeder is recommended for Mig weld-

REGULATOR MIG PROCESS

TO POSITIVE (+) STUD

RECOMMENDED WORK CABLE General Guidelines

OUTPUT CABLE GUIDELINES (Table A.1)

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

Voltage sense leads requirements are based on the weld process

GMAW 67 lead required 21 lead optional (3)

Electrode Voltage Sensing

While most applications perform adequately by sensing the work

Negative Electrode Polarity

VOLTAGE SENSING If Sense Leads ARE Used:

CONTROL CABLE CONNECTIONS Connection Between Power Source and Ethernet

Product specific Installation Instructions

Connection Between Power Source and ArcLink® Compatible

The 5-pin ArcLink control cable connects the power source to

SAFETY PRECAUTIONS GRAPHIC SYMBOLS THAT APPEAR ON

• WELDING SPARKS can cause

POWER-UP SEQUENCE OPERATORS

The duty cycle is based on a ten-minute period. A 40% duty

PRODUCT DESCRIPTION PROCESS LIMITATIONS

RECOMMENDED PROCESSES AND

The POWER WAVE® R500 is recommended for robotic and semiauto-

The POWER WAVE® R500 is a high speed, multi-process power

• Potted PC boards for enhanced ruggedness/reliability.

• Waveform Control Technology™ for good weld appearance

CASE FRONT CONTROLS

1. STATUS LED - (See Troubleshooting Section for opera-

CASE BACK CONTROLS 9. EXTERNAL I/O CONNECTOR: