ADVANCED PROCESS WELDERS

Power Wave S500

®

Processes Input Voltage Rated Output

Stick, DC TIG, Pulsed DC TIG, MIG, 200/208/220/230/380/400/415/460/575/ GMAW: 550A/41.5V/40%
3/50/60 GMAW: 450A/36.5V/100%
Pulsed MIG, Flux-Cored
Input Current @ Rated Output Weight/Dimensions (H x W x D)
Product Number 3 Ph / 40% Duty Cycle: 80/73/41/37/29A 150 lbs. (68 Kg)
K2904-1 Power Wave® S500 3 Ph / 100% Duty Cycle: 60/54/30/27/21 A 22.5 x 14 x 24.8 in.
K3187-1 Power Wave® S500 Ready-Pak® Output Range (571 x 355 x 630 mm)
K3186-1 Power Wave® S500 One-Pak® 5 - 550 Amps
See back for complete specs

Powerful Multi-Process APPLICATIONS

Capability.  Construction
The multi-process Power Wave S500 is packed ®  Aerospace
with Lincoln Electric performance technology  Fabrication
for welding on thicker materials. It provides
an extremely fast arc response, includes over  Automotive
65 standard welding waveforms for optimized  Production
performance on almost any application and
efficiently converts input power to reduce
operational costs.

FEATURES
 PowerConnect™ Technology
(Patent-Pending) - Automatically adjusts
to input power from 200-600V, 50 or 60
Hz, three phase. Welding output remains
constant through the entire input voltage
range.
 Tribrid™ Power Module - Exceptional
welding performance with high power factor
and efficiency.
INPUT OUTPUT
 CheckPoint™ and Production Monitoring™ RECOMMENDED WIRE FEEDERS
2.2 – Use your server or our cloud-based  Power Feed® 10M bench and
server to view and analyze your welding boom models
data on almost any device – desktop, laptop,  Power Feed® 25M
iPhone® or iPad®, Blackberry® and others. IN
CO
LN ELECT
RI

Track equipment usage, store weld data,

C
L

configure fault limits and more. WAVEFORM CONTROL TECHNOLOGY®

 Standard 115V (10A) AC Duplex Auxiliary PROCESS CAPABILITIES
Power Receptacle – Features patent-  Pulse
pending Surge Blocker™ Technology to  Pulse-on-Pulse® Two Year Extended
ensure simultaneous welding performance  Power Mode®
Warranty Available in
is not compromised by high starting current the U.S.A. and Canada.
devices such as grinders (typically requiring  RapidArc®
60A or more peak surge current).  Rapid X™
 Durable Case - IP23 rated to withstand  Ugradable for additional processes to
harsh environments. be developed in the future. www.lincolnelectric.com/green

 Standard Ethernet - Allows for

effortless software upgrades through
powerwavesoftware.com

ISO
9001:2000
14001:2004
THE LINCOLN ELECTRIC COMPANY
22801 St. Clair Avenue • Cleveland, OH • 44117-1199 • U.S.A.
Publication E5.115 | Issue Date 05/12 PH: 216-481-8100 • www.lincolnelectric.com
© Lincoln Global, Inc. All Rights Reserved.
 KEY CONTROLS

Reversible handles shown

1
8 FRONT
1. Optional S-Series User Interface Kit (K3001-2) for Stick, TIG and CV MIG
with voltage sensing feeder
2 7 2. Status Light
3 3. Thermal Fault Indicator Light
4. Output Studs
4 6 5. Output Control Receptacle Knockout Plate – 12-pin
(for optional output control receptacle included with K3001-2 S-Series
5 User Interface Kit)
6. Work Sense Lead Receptacle
7. Main Power Switch
8. Reversible Handles
17
16
15 BACK
9. Standard 115V (10 Amp) AC Duplex Auxiliary Power Receptacle and
Circuit Breaker
9
10. ArcLink® Welding System Component Communication Cable Receptacle
11. Sync Tandem/STT® Receptacle
12. Optional DeviceNet™ Kit (K2827-1)
13. Input Power Cable Connection
10 14. TIG Solenoid Kit Knockout Plate
14 (for optional TIG solenoid included with K3001-2 S-Series
11 User Interface Kit)
12 15. Ethernet Cable Receptacle
13 16. Circuit Breaker (ArcLink®)
17. Reversible Handles

OPTIONALl K3001-2 S-SERIES USER INTERFACE KIT

To tap into the Power Wave® S500 stick, TIG and CV MIG process capability without
a Power Feed® series wire feeder, add the K3001-2 User Interface Kit. This optional
interface provides full control of welding parameters from the front panel of the power
source for stick and TIG processes. When used with a Power Feed® series wire feeder,
the feeder is typically used for controlling the system and the K3001-2 User Interface
Kit meters can be used for viewing amps and volts. Kit also includes 12-pin Universal
Remote Receptacle and TIG Gas Solenoid.

The User Interface Kit allows control over:

• Volts/Amps Control – Adjust volts in • Advanced Process Options – Control
MIG and flux-cored welding or adjust pre- and post-weld settings to optimize
amperage in stick or TIG welding. arc starts and stops.
• Welding Mode – Select the stick, TIG or • Arc Control – Adjust arc characteristics
CV wire process. to match individual preferences.

[ 2 ] | Power Wave ® S500

 WHAT’S INCLUDED

Ready-Pak® Packages are assembled and shipped on one pallet. One-Pak® Packages are not assembled. All packages can be ordered using a single
Product Number (K#). Welding wire and shielding gas must be ordered separately.

Power Wave® S500/Power Feed® 10M Power Wave® S500/Power Feed® 10M
Bench Feeder Ready-Pak®, includes: Bench Feeder One-Pak®, includes:
• Power Wave® S500 (K2904-1) • Power Wave® S500 (K2904-1)
• Power Feed® 10M Bench Model (K2230-1) • Power Feed® 10M Bench Model (K2230-1)
• Wire Reel Stand • Wire Reel Stand
• ArcLink®/Linc-Net™ Control Cable with • ArcLink®/Linc-Net™ Control Cable with
Weld Power Cable - 8 ft. (2.4 m) Weld Power Cable - 8 ft. (2.4 m)
• Magnum® PRO Curve™ 400 Gun and Cable • Magnum® PRO Curve™ 400 Gun and Cable
Package (K2952-2-10-45) Package (K2952-2-10-45)
• .040-045 (1.0-1.1 mm) Drive Roll Kit • .040-045 (1.0-1.1 mm) Drive Roll Kit
(KP1505-045S) (KP1505-045S)
• Work Lead Package (K2149-1) • Work Lead Package (K2149-1)
• Harris Flowmeter Regulator and Hose
® • Harris® Flowmeter Regulator and Hose
(3100211) (3100211)
Order K3186-1 Shown: K3187-1
• Inverter and Wire Feeder Cart (K3059-2)
Order K3187-1

POWER WAVE® S500 TECHNOLOGIES

Tribrid™ Power Module iARC™ High Speed Digital Controls

Patent-pending Tribrid Power Module features
™ iARC™ (Intelligent Architecture for Regulation and
Lincoln Electric’s PowerConnect™ technology, Control) digital welding controls are more than 10
Planar Transformer™ Technology and 120kHz times faster than the previous generation, with 128
output to provide exceptional welding performance times more RAM, and 8 times more flash memory.
while still maintaining a high power factor and It also features 100Mbps Full Duplex Ethernet to
efficiency. support Lincoln Electric’s Production Monitoring™ 2.2.

CheckPoint™ and Production Monitoring™ 2.2 Rugged Reliability

CheckPoint cloud server-based and mobile
™
Like all Lincoln Electric welding equipment, the
delivery solutions, along with enterprise network- Power Wave® S500 was tested under severe
based Production Monitoring™ 2.2, are the welding conditions to ensure proper operation in the harshest
industry’s most advanced weld data collection and environments:
monitoring tools, allowing fabricators to analyze their
welding operations and processes. These tools can • Extreme Temperature Ranges
provide necessary data for customer ISO, Six Sigma, • Extreme Humidity
statistical process control (SPC), quality cost delivery • Rain
(QCD), overall equipment effectiveness (OEE) and • Dirt and Dust
lean manufacturing efforts. CheckPoint™ Standard • IP23 Rated Performance
Edition is offered at no charge with every Power
Wave® purchase. An advanced capability Premium
Subscription Edition is also available.

RECOMMENDED ACCESSORIES

WIRE FEEDER OPTIONS AutoDrive® 19 Controller AutoDrive® 19 Tandem

Relays wire feed commands from Controller
STT Module
®
Power Wave® S Series power Relays wire feed commands from
This module allows easy
source to any AutoDrive® Series Power Wave® S-Series power
connection and fast digital
robotic wire drive for automated source to any AutoDrive® Series
communication with compatible
welding operation. Not compatible robotic wire drive for automated
Power Wave® S-Series power
with Power Wave® R-Series power tandem welding operations.
sources, Power Feed® wire
sources. Order K3171-1
feeders, and compatible water
Order K3004-1
coolers. Add STT® capability
without having to purchase a
second power source.
Order K2902-1 US/Int’l (shown)
Order K2921-1 CE

Power Wave ® S500 | [ 3 ]

 RECOMMENDED ACCESSORIES
GENERAL OPTIONS Deluxe Adjustable Gas Regulator 12-pin to 7-pin Adapter
& Hose Kit Allows 7-pin push-pull guns to
S-Series User Interface Kit
Accommodates CO2 , Argon, or be used with 12-pin Universal
This kit allows local control of
Argon-blend gas cylinders. Includes Connection.
stick, TIG and wire processes from
the power source control panel.
a cylinder pressure gauge, dual Order K2910-1
scale flow gauge and 4.3 ft.
Includes TIG Solenoid and Remote
(1.3 m) gas hose.
Control Connector.
Order K586-1 TIG OPTIONS
Order K3001-2
PTA-17 150 Amp
Air-Cooled TIG Torch
Weld Fume Control Solutions
DeviceNet Kit™
Lincoln Electric offers a wide Order K1782-1 for 12.5 ft.
The kit allows DeviceNet™
variety of weld fume control (3.8 m) length, 1-cable
connectivity to control the power
solutions, ranging from portable Order K1782-3 for 25 ft.
source. Includes internal harness
systems easily wheeled around (7.6 m) length, 1-cable
and 5-pin DeviceNet™ receptacle
the shop to shop-wide central
for mounting on power source
systems servicing many dedicated
back panel. PTA-26 200 Amp
welding stations.
Order K2827-1 Air-Cooled TIG Torch
Request Publication MC08-70
Order K1783-1 for 12.5 ft.
Inverter and Wire Feeder Cart (3.8 m) length, 1-cable
STICK OPTIONS Order K1783-3 for 25 ft.
Rear-wheeled cart with front
casters and gas bottle platform. Accessory Kit (7.6 m) length, 1-cable
Convenient handles allow for easy Complete kit for stick welding.
cable storage. Small footprint fits Includes 30 ft. (9.1 m) electrode
through 30 in. (762 mm) door. Not cable, 25 ft. (7.6 m) work cable, Parts Kits
intended for use with double head headshield, work clamp and Magnum® Parts Kits provide all the
wire feeders. electrode holder. 150 amps. torch accessories you need to start
Order K3059-2 Order K704 welding. Parts kits provide collets,
collet bodies, a back cap, alumina
nozzles and tungstens in a variety
Work Lead Package Accessory Kit of sizes, all packaged in an easy to
15 ft. (4.5 m) 4/0 cable with 1/2 in. Complete kit for stick welding. carry reclosable box.
stud lug and work clamp. Includes 30 ft. (9.1 m) electrode Order KP508 for PTA-17
Order K2149-1 cable, 25 ft. (7.6 m) work cable, Order KP509 for PTA-26
headshield, work clamp and
electrode holder. 150 amps.
Cool Arc® 55 Order K875 Foot Amptrol™ with
Designed to integrate directly 12-pin Universal Connector
with the Power Wave® S-Series Provides 25 ft. (7.6 m) of remote
power sources, the Cool Arc® 55 Remote Output Control with current control for TIG welding.
is capable of cooling torches rated 12-pin Universal Connector Requires K3001-2 S-Series
up to 500 amps for robotic or Permits remote adjustment of User Interface Kit.
hand-held MIG, TIG, and plasma output. Requires K3001-2 S-Series Order K870-2
cutting applications. 115/1/60 input User Interface Kit.
voltage. Order K857-2 for 25 ft. (7.6 m)
Order K3086-1 Hand Amptrol™ with
12-pin Universal Connector
12-pin to 6-pin Adapter Provides 25 ft. (7.6 m) of remote
Work Voltage Sense Lead Kit Allows older 6-pin remote controls current control for TIG welding.
Required to accurately monitor (K870, K963-3, K857) to be used Requires K3001-2 S-Series
voltage at the arc. with 12-pin Universal Connection. User Interface Kit.
Order K940-25 for 25 ft. (7.6 m) Order K2909-1 Order K963-4
Order K1811-50 for 50 ft. (15.2 m)
Order K1811-100 (shown) for
100 ft. (30.5 m)

PRODUCT SPECIFICATIONS
Net
Product Product Input Input Current Rated Output Output HxWxD Weight
Name Number Voltage @ Rated Output Current/Voltage/Duty Cycle Range inches (mm) lbs. (kg)
Power Wave® S500 K2904-1 200/208/220/230/380/ 3 Ph / 40% Duty Cycle: 80/73/41/37/29 GMAW: 550A/41.5V/40% 5-550A 22.5 x 14 x 24.8 150
400/415/460/575/ 3 Ph / 100% Duty Cycle: 60/54/30/27/21 GMAW: 450A/36.5V/100% (571 x 355 x 630) (68)
3/50/60 SMAW: 550A/42V/40%
Power Wave® S500/ K3187-1 SMAW: 450A/38V/100%
Power Feed® 10M GTAW-DC: 550A/32V/40%
Ready-Pak® GTAW-DC: 450A/28V/100%

Power Wave® S500/ K3186-1

Power Feed® 10M
One-Pak®

For best welding results with Lincoln Electric equipment,

always use Lincoln Electric consumables. Visit www.lincolnelectric.com for more details.

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 information or advice about their use of our products. Our employees respond to inquiries to the best of their ability
based on information provided to them by the customers and the knowledge they may have concerning the application. Our employees, however, are not in a position to verify the information provided
or to evaluate the engineering requirements for the particular weldment. Accordingly, Lincoln Electric does not warrant or guarantee or assume any liability with respect to such information or advice.
Moreover, the provision of such information or advice does not create, expand, or alter any warranty on our products. Any express or implied warranty that might arise from the information or advice,
including any implied warranty of merchantability or any warranty of fitness for any customers’ particular purpose is specifically disclaimed.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility
of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.