Lincoln Electric IDEALARC CV-305 Operator'S Manual Download Page 9

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Three Phase Power

RATING PLATE

Transformer

Rectifier

Rectified DC Output

Constant Voltage Characteristic

Line Connection

Shielded Metal Arc Welding

Flux Cored Arc Welding

Degree of protection provided by the enclosure

IP21

Designates welder complies with National Electrical Manufacturers

Association requirements EW 1.

NEMA EW 1

Summary of Contents for IDEALARC CV-305

Page 1: ...and Distributor Locator www lincolnelectric com locator Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the...

Page 2: ...A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual s...

Page 3: ...rs and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some case...

Page 4: ...to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with su...

Page 5: ...nt passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow N...

Page 6: ...6 Stacking 16 Input Wiring 16 Output Connections 17 Installation of Field Installed Options 17 18 Installation of Equipment Required for Recommended Processes 18 Operating Instructions 19 Safety Preca...

Page 7: ...in describing the function of the various components Below are the symbols used 8 V Input Power On Off Output Voltage Control Increase Decrease of Output Voltage OUTPUT CONTROL DIAL POWER ON OFF SWITC...

Page 8: ...9 Circuit Breaker CIRCUIT BREAKER High Temperature THERMAL PROTECTION LIGHT Voltmeter VOLTMETER SWITCH Positive Electrode Negative Electrode...

Page 9: ...DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Degree of protection provided by the enclosure IP21 Designates welder complies with Nationa...

Page 10: ...11 Warning Identification WARNING IDENTIFICATION Signifying the Earth Ground Connection EARTH GROUND CONNECTION Signifying the Chassis Ground Connection CHASSIS GROUND CONNECTION...

Page 11: ...e control a small 2 watt poten tiometer is calibrated from 1 to 10 MACHINE OUTPUT CONTROL SWITCH LOCAL OR REMOTE The machine output voltage can be controlled by either the OUTPUT COnTROL on the machin...

Page 12: ...ed behind the control panel which hinges down for easy access to the board The Snubber PC Board is mounted on the back of the case front MACHINE COOLING The fan pulls air in through the louvered front...

Page 13: ...If the machine is overloaded the primary thermostat will open the output will be zero and the thermal protection light will be on the fan will continue to run The secondary thermostat will open either...

Page 14: ...Remote Control Adapter Cable 115V Starter Circuit Suitable Undercarriages Remote output Control Other Features net Weight Dimension Print Wiring Diagram Standards Compliance Operating Temperature CV 4...

Page 15: ...ted inside the access panel cover See Installation Data below ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground...

Page 16: ...give the same control as the output control on the machine REMOTE CONTROL ADAPTER CABLE K864 A V cable 12 30m long to connect a K857 Remote Control 6 pin connector with a wire feeder 14 pin connector...

Page 17: ...erminal strip marked with the symbol for connecting the auto matic equipment grounding wire See the appropriate connection diagram for the exact instructions for the wire feeder being used Refer to 11...

Page 18: ...l at the right of the control panel is a continuous control of the machine output voltage The control may be rotated between minimum and maximum to adjust the machine output even while welding The mac...

Page 19: ...lectrode for the remote 21 work sens ing lead VOLTMETER SWITCH Select for positive electrode or for negative electrode This switch selects electrode polarity for the remote 21 work sensing lead of aut...

Page 20: ...nd the fan will continue to run When the thermostats reset the protection light will be off The power source is also protected against overloads on the SCR bridge assembly through the solid state faul...

Page 21: ...leads 3 Check input voltage at contactor 4 Check voltage against instruc tions 5 Replace coil 6 Replace switch 1 Make sure trigger circuit is being closed 2 Repair connection 3 Repair 4 Replace See P...

Page 22: ...en in control circuit 5 Faulty Control PC Board 1 Check position of switch 2 Check switch and replace if faulty 3 Check wiring and control PC Board wiring harness plugs 4 Replace See Procedure for Rep...

Page 23: ...ulty 4 Check all leads and connections internal or remote for continuity repair if necessary 5 Replace See Procedure for Replacing PC Boards 1 Work connection must be ade quate for application 2 Adjus...

Page 24: ...550 amps if a short or overload is applied to the machine CHECKING SNUBBER PC BOARD In case of an SCR malfunction or failure the Snubber PC Board should be checked Turn the machine off and remove the...

Page 25: ...2 and 3 2 Power Diode Test a Establish the polarity of the ohmmeter leads and set to X10 scale b Connect the ohmmeter positive lead to anode and negative lead to the cathode c Reverse the leads of the...

Page 26: ...O SNUBBER BOARD SHUNT P5 221 222 223 204 220 204 204 204 220 D1 D2 D3 SCR1 SCR2 SCR3 G1 G2 G3 D4 ANODE CATHODE ANODE CATHODE P3 Gate leads plug to Control P C board To T1 main transformer To plug P1 T...

Page 27: ...vered 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 replacemen...

Page 28: ...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 f...

Page 29: ...CV400 NOTES...

Page 30: ...CV400 NOTES...

Page 31: ...CV500 I RETURN TO MAIN INDEX Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Illustration of Sub Assemblies Illustration of Sub Assemblies Illustration...

Page 32: ...P 236 A P 236 A 08 05 2011 CV 400 CV 500 I ILLUSTRATION OF SUB ASSEMBLIES Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies 5 5 4 4 7 7 1 1 6 6 2 2 3 3...

Page 33: ...00 I 1 1 1 1 1 1 1 1 220 380 440 11087 CV400 1 2 1 1 1 1 1 1 230 460 575 3 60 11088 CV400 1 2 1 1 1 1 1 1 230 460 575 3 60 11089 CV400 1 2 1 1 1 1 1 1 230 460 575 3 60 08 05 2011 CV 400 CV 500 I Do No...

Page 34: ...1 230 460 3 60 10085 CV400 1 208 3 60 10086 CV400 1 575 3 60 10087 CV400 1 230 460 575 3 60 10088 CV500 I 1 220 380 440 3 50 60 10089 CV500 I 1 380 500 3 50 60 10090 CV500 I 1 415 3 50 60 10091 CV500...

Page 35: ...2 1 230 460 575 11356 CV500 I 1 1 1 1 1 1 3 1 220 380 440 w Meters 11835 CV400 1 2 2 1 1 1 2 1 230 460 11836 CV400 1 2 2 1 1 1 2 1 230 460 575 11837 CV500 I 1 1 2 1 1 1 3 1 220 380 440 w Meters Covers...

Page 36: ...Contact the Service Department for any code numbers not listed CV400 CV500 I For Codes 10084 to 11837 CODE NO 11354 CV400 1 230 460 11355 CV400 1 230 460 575 11356 CV500 I 1 220 380 440 w Meters 1183...

Page 37: ...K817 P Undercarriage 3 Wheels CV500 I Order K817 Undercarriage 3 Rubber Wheels CV500 I Order K817 R Welding Cable Plug 1 0 2 0 or 50 70MM 2 CV500 I Order K852 70 Welding Cable Plug 2 0 3 0 or 70 95MM...

Page 38: ...tion Diagram Code 10092 M17037 1 X Ground Decal Rear of Machine T13259 1 X Ground Decal T13260 4 1 X Identification Sticker CR1 T14798 1 1 X Caution Decal S13504 1 X Warning Decal Domestic M16196 1 X...

Page 39: ...CV 400 CV 500 I NOTES Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies...

Page 40: ...x of Sub Assemblies Index of Sub Assemblies Part Numbers Part Numbers Part Numbers Part Numbers 4A 4A 4B 4B 13 13 11 11 10A 10A 10B 10B 12B 12B 12A 12A 5 5 3B 3B 3A 3A 3C 3C 14A 14A14B 14B14C 14C 7B 7...

Page 41: ...crew S8025 15 2 X X 11 Number Plate S18378 1 1 X X 12A Terminal Strip TS1 S14530 12 1 X X 12B Self Tapping Screw S8025 62 2 X X 13 Capacitor Assembly C6 T14824 1 X X 14A 1 2 13 x 75 HHCS CF000020 2 X...

Page 42: ...Numbers Part Numbers Part Numbers Part Numbers 3A 3A 2B 2B 2C 2C 2D 2D 2A 2A 4A 4A 4B 4B 1A 1A 12C 12C 12A 12A 12C 12C 12B 12B 11 11 Welded to Box Welded to Box 10F 10F 6 6 1B 1B 5B 5B 3C 3C 12D 12D...

Page 43: ...3 1 X 9B Self Tapping Screw S8025 65 3 X X 10 Reconnect Panel Assembly Includes 220 380 440 L7219 1 1 X 10A Reconnect Panel M15002 1 1 X 10B Reconnect Panel Link T14190 1 6 X 10C Reconnect Panel Link...

Page 44: ...0F Grommet Strip T12823 13 1 X 10G E2521 1 010 5 13 7 20 NSS 1 X 10 Reconnect Panel Asbly 230 460 Code 11835 Includes L7219 11 1 X X 10A Reconnect Panel M15002 5 1 X X 10B Reconnect Panel Link T14190...

Page 45: ...X 15A Receptacle Lead Asbly CV500 I Not Shown S19655 1 X X 15B Self Tapping Screw CV500 I Not Shown S8025 62 2 X X 15C Plain Washer CV500 I Not Shown S9262 3 2 X X 16 220V 2A Decal CV500 I Not Shown T...

Page 46: ...rt Numbers Part Numbers 4E 4E 4C 4C 4B 4B 16 16 3 3 4D 4D 4C 4C 4B 4B 13 13 14 14 12 12 7C 7C 7B 7B 7A 7A 3 3 12 12 14 14 13 13 11 11 4B 4B 4A 4A Part of Bridge Part of Bridge Assembly Assembly 9 9 6A...

Page 47: ...ng Bracket S17355 1 X 15B Thread Forming Screw S9225 8 1 X 16 Lead Insulating Panel S18666 1 X 17 Capacitor Assembly Includes 17A thru 17J M14495 3 1 X 17A Capacitor Bracket S17354 1 X 17B Insulation...

Page 48: ...F P 236 F 08 05 2011 CV 400 CV 500 I Transformer Assembly Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Part Numbers Part Numbers Part Numbers Part Nu...

Page 49: ...60 Code 10092 G2589 3 9852 1 X 1 Transformer Asbly 220 380 440 3 50 60 Code 10277 G2589 3 9852 1 X 1 Transformer Asbly 415 3 50 60 Code 10278 G2589 6 9857 1 X 1 Transformer Asbly 230 460 Code11835 M12...

Page 50: ...10A Part of 10A 10B 10B 10B 10B Part of 10A Part of 10A 12B 12B 12A 12A 10A 10A 12B 12B12C 12C12D 12D 8D 8D 8C 8C 2 2 6E 6E 9B 9B 9C 9C 9D 9D 10A 10A 4C 4C 14 14 8A 8A 8B 8B 11A 11A11B 11B 7 7 16A 16...

Page 51: ...X 11A 5 16 18 x 1 50 HHCS CF000081 3 X 11B Plain Washer S9262 30 3 X 12A 5 16 18 x 1 50 HHCS CF000081 1 X 12B Plain Washer S9262 30 2 X 12C Lock Washer E106A 14 1 X 12D 5 16 18 HN CF000029 1 X 13 Snu...

Page 52: ...in the column under the heading number called for in the model index page Indicates a change this printing P 236 G 2 ITEM DESCRIPTION PART NO QTY 1 2 3 4 5 6 7 8 9 P 236 G 2 Index of Sub Assemblies I...

Page 53: ...CV 400 CV 500 I NOTES Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies...

Page 54: ...ex of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Part Numbers Part Numbers Part Numbers Part Numbers 1 1 6A 6A Part of 13A Part of 13A 15 15 Part of 8 Part of 8 3 3 5 5 9 9 10 10 P...

Page 55: ...B 4 X X 13A D C Voltmeter with Meters M15538 1 1 X 13A D C Voltmeter M21002 1 1 X X 13B Plain Washer Not Shown S9262 39 4 X X X 13C 4 40 HN Not Shown CF000002 4 X X 13D Lock Washer Not Shown T4291 B 4...

Page 56: ...2011 CV 400 CV 500 I Covers Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Index of Sub Assemblies Part Numbers Part Numbers Part Numbers Part Numbers 1A 1A 3 3 5 5 1B 1B 4 4...

Page 57: ...Warranty Decal Domestic S22127 2 1 X 6 Decal Product Name M21954 2 1 X 7 Decal LECO Logo S27368 3 1 X 08 05 2011 CV 400 CV 500 I Use only the parts marked x in the column under the heading number cal...

Page 58: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra...

Page 59: ...d Entl ftung des Arbeitsplatzes l Mantenha seu rosto da fuma a l Use ventila o e exhaust o para remover fumo da zona respirat ria l Turn power off before servicing l Desconectar el cable de ali mentac...

Page 60: ...tomer 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...

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