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Lincoln CV-525, Operator'S Manual

The Lincoln CV-525 is a high-performance welding machine designed for professionals. Enhance your productivity with this versatile equipment. To gain full control of its features, download the free Operator's Manual from our website and unlock the potential of your Lincoln CV-525.

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F-1

DIAGRAMS

F-1

CV-525

H2
H3

H4

CHOKE

OUTPUT

L1

206

205

225

VM

231

224

75

211

10K      /2W

OUTPUT

CONTROL

S2

OUTPUT CONTROL

SWITCH

76

211

213

77

SWITCH

POWER

S1

J11

8

7

4

3

2

1

201
202

203

204

4

1

2

3

4

AUXILIARY

10

7

P2

4

2

1

7

8

9

3

SNUBBER

BOARD

204

224

225

223

222

221

220

D2

D3

SCR1

SCR2

D4

204

204

205

206

OPTION

204

R2

220

204

7.5     /100W

C2

C3

C4

C5

+

+

+

+

+

31,000MFD

50V EACH

10A
SLOW
BLOW

CAPACITOR
DISCHARGE

RELAY

CR4

X1

232

31

32A

CONTACTOR

CR1

X1

233

TO SUPPLY LINES

11

12

3

6

FAN MOTOR

H1

CONNECT OR
INSULATE AS
SHOWN ON
INPUT
CONNECTION

DIAGRAM

+

-

SCR3

TO GROUND PER
NATIONAL ELECTRICAL

CODE

H

3
2

1

CONTROL BOARD

AM

224

210

R4

212

210

232

PILOT
LIGHT

J12

6

5

1

2

3

4

J13

COILS

PRIMARY

TOP

BOTTOM

PRIMARY

6

J2

D1

SCR1

G3

G2

G1

204

205

206

SHUNT

C1

C2

C3

C4

C5

254

204

0.5    /50W

R7

R8

F2

4

231

231

115V

X2

115V

9

8

SCR3

L1

L2

L3

W

V

U

41

302

2

41

41

SECONDARY

PRIMARY

CIRCUIT

BREAKER

42A

S

241

115V

S

10A

CIRCUIT

BREAKER

2
240

42B

LIGHT

W

233

10AMP

THERMOSTAT

THERMOSTAT

H1

41

DIODE

Case Front R.H.

Grounding Stud

+

-

206

THERMAL

PROTECTION

X3

SEC

X2

SEC

X1

SEC

RECTIFIER
ASSEMBLY

220

220

224

31 41

21

75

4

2

32

10A

CIRCUIT

BREAKER

32A

225

C6

.0047MFD

1400V

Y

233

TRANSFORMER

T2 CONTROL

VOLTMETER

SWITCH

S3

21

225

PRIMARY CONNECTION TABLE

PRIMARY VOLTAGE

CONNECTION DAIG.

8

7

4

3

2

1

206
212

206

205

220

6

5

213

75

205

GREEN

CAPACITOR
DISCHARGE
OPTION

N.A.

N.C.

LEAD NOT PRESENT
WITH DIODE OPTION

0.5    /50W

H5

SEE PRIMARY
CONNECTION TABLE

2

5

1

4

36

35

+

-

225

N.A.

8

7

4

3

2

1

6

5

16

15

14

9

J1

8

7

4

3

2

1

6

5

12

11

10

9

14

13

16

15

J7

8

7

4

3

2

1

6

5

12

11

10

9

14

13

16

15

J3

1001

1002

1003

1004

1009

1010

1011

1013

1014

1015

4

3

2

1

6

5

J8

2

1

J9

FEEDER

INTERFACE

BOARD

MOTOR

DRIVE

BOARD

D5

1005A

1006

1008

1012

1016

REED

SWITCH

CR1

42B

32B

115V

42V

303

304

305

306

307

308

311

312

313

314

315

316

304

312

FEEDER
READY
LED

R6

1006

1014

24

23

42B

42

32

S6

ONE MAGNETICALLY

TIGHTLY COUPLED TURN

R5

S4

S5

2 STEP/4 STEP

GAS
PURGE

CRATER
CURRENT

CRATER
VOLTAGE

9

8

4

2

6

1

3

7

5

A

B

C

D

E F

G

H

J

I

K

L N

M

(COMPONENT SIDE OF P.C. BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

ELECTRICAL SYMBOLS PER E1537

2

4 3

1

9 PIN

J2

14 PIN

P6

202

21V

21V

21V

203

201

204

S

S

S

TRANSFORMER

T1 MAIN

24

23

 CV-525  WIRING DIAGRAM     

    AL2466-3

204

WF-O

WF-P

6

5

4

3

2

1

6

5

4

3

2

1

501

502

503

504

505

506

507

508

509

510

511

512

11

10

13

12

309

310

301

302

C

W

C

W

C

W

R

10

R

10

B

U

R

N

B

A

C

K

R

U

N

IN

W

E

LD

T

IM

E

R

S

P

O

T

S

W

IT

C

H

OPTIONAL PANEL

408

407

406

405
404

403

402
401

S7

R

10

R

11

R

12

J4

5

6

1

2

3

4

7

8

CW

301

309

310

32B

42V

24V

240

2

1

J10

1

2

P14

J14

P10

1

2

3

4

5

6

7

8

9

10

11

12

36V

2

J9, J10, J14

1

2

4

3

1

5

6

3

6

4

2

7

8

5
2

5

10

6

4

11

12

9
3

8
2

7
1

7

14

8

6

15

16

5

12

4

11

3

10

2

9
1

13

J13

J8

J4, J11, J12

J5

J1, J3, J7

326

2

4

41

S

Control Panel

Grounding Stud

N.D.

Case Front L.H.

Grounding Stud

Input Box R.H.

Grounding Stud

Input Box

Grounding Stud

35A

M

~

Chg.Sheet
A9-10-02M

P11

P13

P12

P4

J5

P5

P1

P3

P6

P7

P8

P9

1009

302

4

4

380-415V. 50/60Hz.

AT3164-11

220 / 380-415 /  440V   50Hz.

230 / 380-415 /  460V   60Hz.

AM3237-1

N.E.

N.E.

NOTES :

N.A.  CIRCUITRY PRESENT ON

CAPACITOR DISCHARGE ONLY

N.B. TAPE UP SEPARATELY TO PROVIDE

AT LEAST 600V. INSULATION

N.C. CIRCUITRY PRESENT ON DIODE OPTION ONLY

N.D. THIS CONNECTION DOSE NOT APPEAR

ON 220/380/440V. MACHINE

N.E. NEWER MACHINES DO NOT HAVE A CASE FRONT R.H.

GROUNDING STUD. SAID STUD WILL COMBINE WITH

THE CASE FRONT L.H. GROUNDING STUD.

N.F.   LEADS TO PASS THROUGH L4 THREE TIMES, AND
          THROUGH  L2 & L3 ONE TIME.

1005B

L3

L2

L4

L1

N.F.

N.F.

Summary of Contents for CV-525

Page 1: ... you act and be careful CV 525 LINCOLN ELECTRIC For use with machines having Code Numbers A1677 Sales and Service through Subsidiaries and Distributors Worldwide The Lincoln Electric Company Australia Pty Ltd 35 Bryant Street Padstow Sydney 2211 Australia Phone 02 9772 7222 FAX 02 9792 1387 World s Leader in Welding and Cutting Products Date of Purchase Serial Number Code Number Model Where Purcha...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for 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 welders ...

Page 4: ...event the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings 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 prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Page 6: ... of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction transmitted through power lines or radiated through space similar to a radio transmitter When emissions are elec...

Page 7: ...lectromagnetic Compatibility EMC product standard for arc welding equipment 1 1 ELECTROMAGNETIC COMPATIBILITY EMC that are taking place The surrounding area may extend beyond the boundaries of the premises Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations If interference occurs it may be necessary to take additional precautions s...

Page 8: ... information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received ...

Page 9: ...n B 5 Solid Sate Output Control B 6 Solid State Control Systems B 6 Machine Cooling B 6 Case Features B 6 Parralleling B 6 Diode Option B 6 Machine And Circuit Protection B 6 Power Source Operation B 7 Control Settings and Descriptions B 7 B 8 Control Features on Feeder Interface Board B 9 ________________________________________________________________________________ Accessories Section C Semi A...

Page 10: ...increases RECOMMENDED INPUT WIRE AND FUSE SIZES Standard Voltage 380 415V 50 60Hz KA1454 1 220 380 415 440V 50 60Hz KA1454 2 50 Duty Cycle 48 83 48 41 45 Duty Cycle 49 84 49 42 100 Duty Cycle 45 77 45 39 60 Duty Cycle 47 81 47 40 Input Current at Rated Output RATED OUTPUT INPUT VOLTAGE 380 415V 220 380 415 440V TYPE 75 C SUPER LAG OR BREAKER SIZE AMPS 1 100A 175A 100A 80A TYPE 75 C GROUND WIRE IN ...

Page 11: ...arc CV 525 grounding terminal located on the welder near the recon nect panel to a good electrical earth ground WARNING STACKING The units may be stacked three high by observing the following safety precautions A Make sure the first or bottom unit is setting on a level well supported surface B The units must be stacked with their fronts flush making sure the two holes in the base rails of the unit...

Page 12: ...This circuit mounts inside the CV 525 and is Recommended when 1 CV 525 is used in conjunction with any LN 23P or older LN 8 or LN 9 semiautomatic wire feeder Eliminates possible arc flash re start of weld when trigger interlock is used Not required with current LN 8 above Code 8700 or LN 9 s with serial numbers above 115187 manufactured after 12 83 or any LN 9 having an L6043 1 Power PC Board 2 CV...

Page 13: ...CV 525 TO LN 22 OR LN 25 a Turn off all power b Connect a jumper between pins C to D in WF L connector plug a K484 14 pin jumper plug is available c Connect the electrode cable to the output terminal of polarity required by electrode Connect the work lead to the other terminal d Place the OUTPUT CONTROL Switch at LOCAL position unless a Remote Control is connected to the CV 525 NOTE The output ter...

Page 14: ...symbols in describing the function of the various components Below are the symbols used V Input Power On Off Output Voltage Control Export Model Increase Decrease of Output Voltage OUTPUT CONTROL DIAL POWER ON OFF SWITCH Remote Output Voltage Control Local Output Voltage Control OUTPUT CONTROL LOCAL REMOTE SWITCH ...

Page 15: ...ER SWITCH Positive Electrode Negative Electrode Warning Identification WARNING IDENTIFICATION Signifying the Earth Ground Connection EARTH GROUND CONNECTION Signifying the Chassis Ground Connection CHASSIS GROUND CONNECTION SYMBOLS USED ON NAMEPLATES AREAS ON THE MACHINE AND IN THIS MANUAL Gas Purge Crater Current A ...

Page 16: ... Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding V Flux Cored Arc Welding Crater Voltage Wire Feeder Spot Weld 2 Step 4 Step Burn Back Run In Speed t t ...

Page 17: ...acle of 36VAC auxiliary power and a circuit breaker are located at the back of the machine for gas heaters RECOMMENDED PROCESSES EQUIPMENT The CV 525 is recommended for use with all the pro cedures of solid wire Gas Metal Arc cored wire outer shield GMA as well as Innershield process within its capacity of 60 to 525 amps This power source is designed to work with Lincoln s Automatic wire feeders a...

Page 18: ...TOR RECEPTACLE F 7 6 G 7 5 H 2 1 I 4 1 J 3 1 K 4 2 A 3 2 B G N D C 2 D 4 E 7 7 L N M REMOTE CONTROL CONNECTIONS Remote control connections are available both at a 14 pin connector receptacle located on the control panel for standard Lincoln wire feeders and the two 6 pin receptacles for Asian style wire feeders GAS HEATER CONNECTOR A standard 3 pin receptacle located on the rear panel for supplyin...

Page 19: ...OL TRANSFORMER LEADS TO INPUT SIDE OF 1CR STARTER AS SHOWN 3 INSULATE THE UNUSED H2 H4 LEAD TERMINALS WITH ADEQUATE TAPE TO PROVIDE AT LEAST 600V INSULATION 4 CONNECT TERMINAL MARKED TO GROUND PER NATIONAL ELECTRICAL CODE CONNECTION FOR 230 VOLTS 50 60Hz 1 ON RECONNECT PANEL LOOSEN ALL HEX BOLTS PULL BACK MOVABLE LINKS AND ROTATE LINKS TO THEIR NEW POSITIONS POPSITION EACH LINK BETWEEN THE WIRE TE...

Page 20: ...ID 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 applications SOLID STATE CONTROL SYSTEM The Control PC Board is located 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 The feeder interfa...

Page 21: ...f the two protective thermostats has opened Output power will be removed when the light is ON POWER SOURCE OPERATION When using a CV 525 power source with wire feeders there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger When used with some wire feeders with the electrical trigger interlock in the ON position the arc can restar...

Page 22: ...is switch selects the control mode of the output voltage either at the power source LOCAL or at the wire feeder remote control box REMOTE 19 ARC VOLTAGE CONTROL Arc voltage can be set from the power source through the 10K potentiometer which is calibrated from 1 to 10 OPTIONAL CONTROL PANEL The following optional control features are not included with the CV525 but come with a optional control pan...

Page 23: ... time It minimizes the ball size at the front of the wire B 10 OPERATION B 10 CV 525 8 5 16 9 6 1 7 12 RSU5W RSU5W SO8 1 4 5 8 SO8 1 4 5 8 SO16 1 8 9 16 SO14 1 7 8 14 SO14 1 7 8 14 SO14 1 7 8 14 SO14 8 14 SO14 1 7 8 14 SO16 1 8 9 16 SO14 1 7 8 14 SO14 1 7 8 14 SO14 1 7 8 14 SO14 1 7 8 14 1 SQF44 44 1 SO16 1 8 9 16 SO14 1 7 8 14 1 9 XCDV10 SO14 1 7 8 14 SO14 1 7 8 14 SO14 1 7 8 14 R2512 SOT23 3 1 2...

Page 24: ...nector on the CV 525 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 and the machine 14 pin connec tor If a remote control is used alone the wire feeder connection is then not used UNDERCARRIAGES K817P K841 For easy moving of the machine optional undercar riages are available with polyolefin wheels K817P o...

Page 25: ... Blow out the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on inter nal parts 3 Periodically check the welding cables Inspect for any slits or punctures Also make sure that all con nections are tight ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before...

Page 26: ...CAUSE lists 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 to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized...

Page 27: ... the machine 1 Faulty input contactor CR1 2 Low line voltage 1 Supply line fuse blown 2 Contactor power circuit dead 3 Broken power lead 4 Wrong input voltage 5 Open input contactor coil 6 POWER I O switch S1 not closing 1 Circuit between 2 C and 4 D is not being closed 2 Electrode or work lead loose or broken 3 Open main transformer T1 pri mary or secondary circuit 4 Defective Control PC Board 5 ...

Page 28: ...sh welding arc 1 Output Control Local Remote switch S2 in wrong position 2 Output Control switch faulty 3 Open in feedback circuitry 4 Faulty Control PC Board 5 Output control potentiometer cir cuit open Lead 75 1 One input fuse blown 2 One phase of main transformer open 3 Faulty Control PC Board 4 Output control potentiometer defective 5 Output control potentiometer Leads 210 211 or 75 open 1 Inp...

Page 29: ... 3 Faulty remote control potentiome ter 4 Leads or connections open in control circuit 5 Faulty Control PC Board 1 Poor work connection 2 Improper procedures 3 Defective Control PC Board 1 Defective Control PC Board 2 Capacitor s in output circuit failed A failure is indicated if the small vent plug on top of a capac itor is raised or blown out 1 Either ground loop fault or aver age current shunt ...

Page 30: ... 1015 4 3 2 1 6 5 J8 2 1 J9 FEEDER INTERFACE BOARD MOTOR DRIVE BOARD D5 1005A 1006 1008 1012 1016 REED SWITCH CR1 42B 32B 115V 42V 303 304 305 306 307 308 311 312 313 314 315 316 304 312 FEEDER READY LED R6 1006 1014 24 23 42B 42 32 S6 ONE MAGNETICALLY TIGHTLY COUPLED TURN R5 S4 S5 2 STEP 4 STEP GAS PURGE CRATER CURRENT CRATER VOLTAGE 9 8 4 2 6 1 3 7 5 A B C D E F G H J I K L N M COMPONENT SIDE OF...

Page 31: ...AM 1 PLUG TO 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 To side of capacitor bank _ X1 X2 X3 GATE _ ...

Page 32: ...NOTES CV525 ...

Page 33: ...NOTES CV 525 ...

Page 34: ...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 de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 35: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 36: ...rough Subsidiaries and Distributors Worldwide The Lincoln Electric Company Australia Pty Ltd 35 Bryant Street Padstow Sydney 2211 Australia Phone 02 9772 7222 FAX 02 9792 1387 World s Leader in Welding and Cutting Products ...

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