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27

REMOTE CONTROL CHECK

Disconnect the remote output control and connect an
ohmmeter across 75 and 76 and rotate the rheostat in
the remote control. The resistance reading should go
from zero to 10K ohms. Repeat with ohmmeter across
77 and 76 with same results. Connect ohmmeter
across 75 and 77. The reading should be 10K ohms.
A lower reading will indicate a shorted or partially
shorted rheostat. A very high reading will indicate an
open rheostat. In either of the last two cases, replace
rheostat. Check cable for any physical damage.

POWER RECTIFIER BRIDGE ASSEMBLY
CHECKING PROCEDURE

1. Bridge and Device Isolation

Disconnect the following, shown in Diagram 1:

a. Unplug P3 (G1, G2, G3, and 204) from the Control

PC Board.

b. Unplug P5 from the Snubber PC Board.

c. Secondary leads X1, X2, and X3 from the anodes

of the SCRʼs and cathodes of the diodes.

d. Disconnect positive bridge lead from shunt and

positive capacitor bank lead and from lug with dual
204 leads.

e. Perform following steps 2 and 3. If diodes and

SCRʼs are not shorted, bridge test is completed. If
any device appears shorted, disconnect the cath-
ode lead of each diode (4 total) and repeat steps 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 ohmmeter from Step b.

d. A shorted diode will indicate zero or an equally low

resistance in both directions. An open diode will
have an infinite or high resistance in both direc-
tions and a good diode will have a low resistance
in Step b. and a much higher resistance in Step c.

3. Power Silicon Controlled Rectifier Test

The SCR must be mounted in the heat sink when
making this test.

a. Connect the ohmmeter (set to the X10 scale) leads

to the anode and cathode.

b. Reverse the leads of the ohmmeter from Step a.

c. A shorted SCR will indicate zero or an equally low

resistance in one or both directions.

d. Establish the polarity of the ohmmeter. Connect

the positive lead to the gate and the negative lead
to the cathode.

e. An open gate circuit will have an infinite or high

resistance. A good gate circuit will read a low
resistance, but not zero ohms. If gate circuit reads
zero ohms, check gate harness for shorts between
gate leads and 204 before replacing SCR.

ELECTRIC SHOCK

can kill.

• Have an electrician install and service

this equipment.

• Turn the input power off at the fuse

box before working on equipment.

• Do not touch electrically hot parts.

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WARNING

Summary of Contents for IDEALARC CV500-I

Page 1: ...512345 IM481 C Issue D ate 11 Aug Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 10088 10089 10090 10091 10092 10277 10278 10279 11356 11837 Register your machine www...

Page 2: ...ER 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 o...

Page 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both weld...

Page 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to preven...

Page 5: ...pri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan...

Page 6: ...important when identifying the correct replacement parts CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables...

Page 7: ...ng 16 Input Power Connections 16 Output Cable Connections 17 Installation of Field Installed Options 17 18 Installation of Equipment Required for Recommended Processes 18 Operating Instructions 19 Saf...

Page 8: ...n of the various components Below are the symbols used 8 V Input Power On Off Output Voltage Control Export Model Increase Decrease of Output Voltage OUTPUT CONTROL DIAL POWER ON OFF SWITCH U Output V...

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

Page 10: ...nments with increased hazard of electric shock European model only Flux Cored Arc Welding Degree of protection provided by the enclosure IP21 Designates welder complies with National Electrical Manufa...

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

Page 12: ...mance is achieved with a fixed pinch setting optimized for the most popular arc characteris tics OUTPUT VOLTAGE CONTROL The OUTPUT voltage control a small 2 watt poten tiometer is calibrated from 1 to...

Page 13: ...circuit SOLID STATE OUTPUT CONTROL The output of the welder is electronically controlled by SCR s instead of mechanical contactors providing extra long life for highly repetitive welding applica tion...

Page 14: ...uit 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 ei...

Page 15: ...er Circuit Suitable Undercarriages Remote output Control Other Features Net Weight Dimension Print Wiring Diagram Standards Compliance Operating Temperature CV 500 I K1347 50 60 Hz DC 500 450 400 40 3...

Page 16: ...er 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 Always wear dry insulating glo...

Page 17: ...marked with the symbol on the machine These terminals are located behind the control panel on the front of the power source This control will give the same control as the output control on the machine...

Page 18: ...strip connectors The control cable from the wire feeding equipment is connected to the terminal strips behind the control panel A strain relief box connector is provided for access into the terminal s...

Page 19: ...t control dial 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 we...

Page 20: ...be applied to the welder 115 VAC and 42 VAC AUXILIARY POWER AND CONTROL CONNECTIONS 14 Pin Connector The 14 pin connector receptacle type MS 3102A 20 27SX supplies auxiliary power 42 VAC is available...

Page 21: ...t overloads on the SCR bridge assembly through the solid state fault protection circuit This circuit senses an overload on the power source and limits the output to approxi mately 550 amps by phasing...

Page 22: ...s the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states t...

Page 23: ...r replace 2 Check input power 1 Replace if blown look for reason first 2 Check control transformer T2 and associated leads 3 Check input voltage at contactor 4 Check voltage against instruc tions 5 Re...

Page 24: ...S2 in wrong position 2 Faulty Output Control switch 3 Faulty Output Control potentiometer 4 Leads or connections open in control circuit 5 Faulty Control PC Board 1 Check position of switch 2 Check s...

Page 25: ...is raised or blown out 1 Place switch in Remote 2 Check and replace if found faulty 3 Check and replace if found faulty 4 Check all leads and connections internal or remote for continuity repair if n...

Page 26: ...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 27: ...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 28: ...A N E U R O P E A N R A N G E C H E C K T H A T T H E C O N N E C T O R B O O T I S M A R K E D F O R T H E A P P R O P R I A T E C A B L E S I Z E P E R T A B L E B E L O W A N D S K I N C A B L E J...

Page 29: ...NUBBER 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 To s...

Page 30: ...ccurate 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...

Page 31: ...h electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 32: ...te Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentac...

Page 33: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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