Lincoln Electric IM481-B User's Manual
Contents
1. RECTIFIER ASSEMBLY Sr Tu CAPACITOR DISCHARGE OPTION N A Ba 0 5 N 50W Q a O 0 5 N SOW 4 le R7 le R8 Le GE N C aes pt Aa 4 Dobel T na el OPTION Lu 31 000MFD 204 50V EACH SHUN a 204 HS 75NA100W Lao NOT PRESENT 204 SNUBBER BOARD 205 206 WITH DIODE OPTION 224 s3 VOLTMETER SWITCH 225 P3 4 0047MFD 1400V Ostet l 5 1 TS2 19 32 L1 CONTROL BOARD gt 12 205 gt 2 gt 206 ELECTRICAL SYMBOLS PER 1 73 gt 212 i gt 4 gt 220 gt 5 gt 205 3 1 ER 6 gt 206 i 4 PIN 8 PIN gt 7 gt 213 R 1 J3 J1 J2 amp J5 De AE 76 CONNECTOR CAVITY Fr TS1 0 75 pe OUTPUT CHOKE l o769 l 1 77 LT Y 32 K BREAKER o O O o 32A NUMBERING SEQUENCE E COMPONENT SIDE OF P C CONTROL BOARD BOARD GROUNDING LEAD NOTES N A CIRCUITRY PRESENT ON CAPACITOR DISCHARGE ONLY N B TAPE UP SEPARATELY N F lt A TO PROVIDE AT LEAST GROUNDING STUD E 210 a2. 3 0 3 0 3 0 85 mm2 85 mm2 3 0 3 0 85 mm2 85 mm2 4 0 107 mm2 107 mm2 150 200 ft 46 61 m 200 250 ft 4 0 67 76 m Installation of Field Installed Options REMOTE OUTPUT CONTROL K857 WITH K864 ADAPTER OR K775 The K857 has a 6 pin MS style connector The K857 requires a K864 adapter cable which connects to the 14 pin connector on the machine The K775 consists of a control box with 28 ft 8 5m of four conductor cable This connects to terminals 75 76 and 77 on the terminal strip and the case grounding screw so 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 STRAIGHT PLUG 14 PIN h TO POWER SOURCE REMOTE CONTROL ADAPTER CABLE K864 CABLE RECEPTACLE 6 SOCKET TO K857 REMOTE CONTROL 000 000 000 CABLE RECEPTACLE 14 SOCKET TO LN 7 WIRE FEEDERS DEG 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 A WARNING ELECTRIC SHOCK can kill e Turn the power switch of the welding power source OFF
3. 75 76 or 77 to the positive output lead the output will be reduced to a low value thus preventing any damage to the machine If the ground occurs between 75 76 77 and the negative output lead one of the PC board self restoring fuses will blow pre venting any machine damage After the ground is cleared the fuses automatically reset within a few seconds Model TECHNICAL SPECIFICATIONS CV 500 l Type K1347 Frequency 50 60 Hz Output Rating Amperes Volts NEMA EW1 IEC 974 1 Duty Cycle DC 450 400 38 36 36 5 34 60 100 Output Range Min Max 60A 12V 500A 42V Max O C V 46 Input Ratings Standard Voltages Single Voltages Available Rated Current Input kVA Power Factor Efficiency Idle Current Idle Power 220 440 220 380 440 230 460 Yes 45A O 400A 34V 380V 50 Hz 29 6 O 400A 34V 50 Hz 65 O 400A 34V 50 Hz 70 400A 34V 50 Hz 3 2A 380V 50 Hz 1 0 KW 50 Hz Optional Features Remote Control Adapter Cable 115V Starter Circuit Suitable Undercarriages Remote output Control Other Features Yes Standard Yes Yes Stackable Case Net Weight Dimension Print 383 Lbs 174 kg M12244 7 Wiring Diagram L9269 Standards Compliance IEC 974 1 S Rated 230 400V only NEMA EW All others IP21 All Operating Temperature 40 C to 40 C INSTALLATION Safety Precautions 44 WARNING e
4. vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand
5. 42 VAC 115 VAC Export Model Only 42 VAC A B C D E F G H J K L M N Terminal Strip Connections Terminal strip TS2 located behind the hinged control panel on the front of the power source supplies 115 VAC A 10 amp circuit breaker protects this circuit This 115 VAC is also available in the 14 pin connector except on the European model Terminal strip TS1 also located behind the hinged control panel allows for connecting of a K775 remote control to terminals 75 76 and 77 A chassis ground screw is provided below the terminal strips marked with the symbol for connecting the automatic equipment grounding wire or remote control grounding wire To gain access to the terminal strips simply remove the two 10 sheet metal screws from the top of the welder nameplate Tilt panel forward so it rests in a horizontal position See Table above for lead number functions 220 VAC AUXILIARY POWER FOR WATER COOLER A Continental European receptacle 220V Schuko type is located on the rear panel for supplying 220VAC to a water cooler 2 amp circuit breaker which is also located on the rear panel protects this circuit from excessive overloads or short circuits MACHINE AND CIRCUIT PROTECTION The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling One thermostat is located on the nose of the center bottom primary coil and a second thermostat is attac
6. SWITCH e zm zm rm rm Remote Output Voltage Control e rm pm rm Local Output Voltage Control CIRCUIT BREAKER THERMAL PROTECTION LIGHT VOLTMETER SWITCH Circuit Breaker High Temperature Voltmeter Positive Electrode Negative Electrode RATING PLATE NEMA EW 1 IEC 974 1 Designates welder complies with National Electrical Manufacturers Association requirements EW 1 Export Model only Designates welder complies with International Electrotechnical commission requirements 974 1 European model only Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Designates Welder can be used in environments with increased hazard of electric shock European model only Degree of protection provided by the enclosure WARNING IDENTIFICATION AN e rm rm rm rm gt Warning Identification EARTH GROUND CONNECTION anm gt Signifying the Earth Ground Connection CHASSIS GROUND CONNECTION zs pm pm em em gt Signifying the Chassis Ground Connection GENERAL MACHINE DESCRIPTION The CV 500 I is an SCR controlled three phase DC power source It is designed with a single range potentiometer control The CV500 I has two models an Export model and a European model The Export model complies with NEMA EW 1 requirements and the European model complies with IEC 974 1 requirement
7. When this option is not used with an NA 3 NA 5 or NA 5R see the CV 500 I NA 3 CV 500 1 NA 5 or CV 500 1 NA 5R connection diagram for instructions on how to disable this circuit If the circuit is not disabled the wire cannot be inched down METER OPTION Factory installed Ammeter and Voltmeter Machine amp Circuit Protection Thermal Protection Light The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling One thermostat is located on the nose of the center bottom primary coil and a second thermostat is attached to the lead connecting the secondaries Both thermostats are connected in a series with the 2 4 circuit 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 with an excessive overload or insufficient cooling The out put will be zero and the protection light will be on 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 an electronic protection circuit This circuit senses an overload on the power source and limits the output to 550 amps by phasing back the SCR s Protection is provided to protect the circuitry from accidental grounds If the customer accidentally grounds
8. ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves 2 FUMES AND GASES can be danger a ous AR e Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone A gt WELDING SPARKS can cause fire or TT explosion Keep flammable material away Do not weld on closed containers ARC RAYS can burn eyes and skin e Wear eye ear and body J protection See additional warning information at front of this operator s manual LOCATION The machine should be located in a clean dry place where there is free circulation of clean air such that air movement in through the front and out through the back will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shut down of the machine APPLICATION LIMITATIONS There are no provisions on the CV 500 I for parallel ing and outdoor operations without rain sheltering is not recommended STACKING WARNING EEZ FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity e Be sure machine is stable when lifting e Do not
9. FOR LOW VOLTAGE N B H3 TO SUPPLY LINES TO GROUNI PER NATION SINGLE VOLTAGE OVER 345 VOLTS TO GROUND PER NATIONAL ELECTRICAL CODE ER N B H2 TO SUPPLY LINES AUXI col BOTTOM 4 PR ELECTRICAL CODE RECONNECT PANEL THIS CONNECTION DOES NOT APPEAR ON 220 380 440V AND 230 400V NACHINES CV 400 CV 500 I D 230 400 VOLTAGE AL FOR 230 V N Bo H3 H2 SHOWN CONNECTED TO SUPPLY LINES TO GROUND 380 500 V PER NATIONAL ELECTRICAL CODE FOR 380 V RECONNECT PANEL WIRING DIAGRAM SHOWN CONNECTED N B e H3 TO SUPPLY LINES ZG CO Enhanced Diagram H3 e H 220 380 440 VOLTAGE SHOWN CONNECTED FOR 220 V TO GROUND PER NATIONAL ELECTRICAL CODE ER RECONNECT PANEL N B TO SUPPLY LINES a L3 L2 L1 7 RECONNECT PANEL TO GROUND PER NATIONAL 2A CIRCUIT BREAKER FAN MOTOR 115V ELECTRICAL a FLEX LEAD JUMPER TO PRIMARY COILS TO PRIMARY COILS Op H1 X1 CONNECT OR INSULATE AS SHOWN ON INPUT CONNECTION LH e 2 DIAGRAM T2 CONTROL TRANSFORMER H 115V x2 231 ed D 2 PRIMARY THERMOSTAT 41 41 gt ILIARY LS T1 MAIN TRANSFORMER CAPACITOR of DISCHARGE IMARY
10. I NOTE The output terminals are energized at all times OPERATING INSTRUCTIONS Safety Precautions WARNING w ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment e Do not touch electrically hot parts e This next section applies to CV 500 I s without the Capacitor Discharge Option When using a CV 500 I power source with wire feed ers there will be a small spark if the electrode con tacts 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 restart if the electrode touches the work or ground during these several seconds POWER SOURCE OPERATION Duty Cycle and Time Period The CV 500 is rated at the following duty cycles Duty Cycle 100 60 50 Based upon a 10 minute time period e for 60 duty cycle it is 6 minutes on and 4 minutes off Overloading the power source may result in opening of an internal protective thermostat as indicated by the amber thermal protection light turning on STARTING THE MACHINE The POWER toggle switch at the extreme right side of the control panel in the 1 position energizes and closes the three phase input contactor from a 115 volt auxiliary transformer This in turn energizes the main power transformer The machine is de
11. L 206 S2 OUTPUT CONTROL SWITCH LT y eRe 10K N 2W OUTPUT THERMAL CONTROL PROTECTION LIGHT OPTIONAL 600 V INSULATION N C CIRCUITRY PRESENT ON DIODE OPTION ONLY PILOT LIGHT Kl Si POWER SWITCH N D THESE LEADS ARE PRESENT WITH METER OPTION ONLY N E 220V WINDING PLUG AND CIRCUIT BREAKER ARE PRESENT ONLY ON CV500 I N F 31 AND 32 ARE NOT PRESENT ON EUROPEAN CV500 I L9269 It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the If the diagram is illegible write to the Service Department for a replacement Give the equipment code number NOTE This diagram is for reference only machine on one of the enclosure panels NOTES NOTES Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese ZS BIR Korean e Do not touch electrically live parts or electrode with skin or wet clothing e 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 e Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung e Isoliere
12. before installing plugs on cables or when connecting or disconnecting plugs to welding power source Sc 0 CAPACITOR DISCHARGE CIRCUIT K828 1 Circuit that mounts inside the CV 500 I Recommended when 1 CV 500 1 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 Y CV 500 I is used with an LN 22 equipped with an older K279 Contactor Voltage Control Option Eliminates electrode overrun when gun trigger is released Not required when later K279 above Code 8800 is used g CV 500 I is used with any semiautomatic wire feeder and possible small spark if electrode touch es work just after gun trigger is released is objec tionable Install per M17060 instructions included with the Kit UNDERCARRIAGES K817P K841 For easy moving of the machine optional undercar riages are available with polyolefin wheels K817P or a platform undercarriage K841 with mountings for two gas cylinders at rear of welder Install per instructions provided with undercarriage Installation of Equipment Required for Recommended Processes WIRE FEEDER CONTROL CABLE CONNECTIONS For control cable with 14 pin connector Connect control cable to 14 pin
13. connector on the front panel of the machine See the appropriate connection diagram for the exact instructions for the wire feeder being used Refer to 115VAC and 42VAC Auxiliary Power and Control Connections section for connector pin functions A cover Lincoln Electric Part Number S17062 3 is available for the unused 14 pin connector to protect it against dirt and moisture For control cable with terminal 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 strip section A chassis ground screw is also provided below the terminal 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 115VAC and 42VAC Auxiliary Power and Control Connections section for access to terminal strips CONNECTION OF CV 500 I TO LN 22 OR LN 25 a Turn off all power b Connect a jumper from 2 to 4 on terminal strip TS2 or jumper pins C to D in 14 pin 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 500
14. the OUTPUT CONTROL on the machine con trol panel the output control on the wire feed unit or an optional remote control that is available This switch selects the mode of control either LOCAL or REMOTE POLARITY SELECTION Polarity selection is made by appropriately connecting the electrode and work welding cables to either the stud or to the stud Select VOLTMETER switch for or electrode for the remote 21 work sensing lead VOLTMETER SWITCH ELECTRODE OR ELECTRODE This switch selects electrode polarity for the remote 21 work sensing lead of automatic or semiautomat ic equipment 115 VOLT POWER SWITCH The power input contactor operates from an auxiliary 115 volt transformer that is energized through the POWER toggle switch on the machine control panel 1 is on and 0 is off PILOT LIGHT A white light on the machine control panel indicates when the power source input contactor is closed This means the main power transformer and all auxiliary and control transformers are energized THERMAL PROTECTION LIGHT An amber light on the machine control panel indicates when either of the two protective thermostats have opened Output power will be removed but input power will still be applied to the machine INPUT CONTACTOR The power source is equipped with an input contactor AUXILIARY POWER CONNECTIONS The power source is e
15. to negative output What To Do Repair or replace 2 Check input power Replace if blown look for reason first Check control transformer T2 and associated leads Check input voltage at contactor Check voltage against instruc tions Replace coil Replace switch Make sure trigger circuit is being closed Repair connection Repair Replace See Procedure for Replacing PC Boards Amber thermal protection light is on Check for overheating make sure fan is operating and there is no obstruction to free air flow Check 75 76 or 77 for ground to positive output circuit Nearly zero ohms to ground indicates a grounded circuit A value greater than a few thousand ohms is nor mal Self restoring fuses on PC Board automatically reset within a few seconds after ground is cleared Check 75 76 or 77 for ground to negative output circuit Nearly zero ohms to ground indicates a grounded circuit A value greater than a few thousand ohms is nor mal Self restoring fuses on PC Board automatically reset within a few seconds after ground is cleared Trouble Machine has low output and no con trol Machine does not have maximum output Machine will not shut off Variable or sluggish welding arc Output control not functioning on the machine Cause Output Control Local Remote switch S2 in wrong position Output Control switch fau
16. 78 75 45 43 39 Ambient temperature of 40 C 104 F At rated output of 400A 100 duty cycle kkk heating and possible fire damage 8 10mm 100 REN 100 8 10mm 100 REN 100 10 5 3mm 60 RES 60 10 5 3mm 60 RES 60 10 5 3mm 50 RES 50 Use only Bussmann Super Lag fuses specified Other fuses may not protect the welder and may cause over A CAUTION Failure to follow these instructions can cause immedi ate failure of components within the machine When powering welder from a generator be sure to turn off the welder first before generator is shut down in order to prevent damage to welder Output Cable Connections The output leads are connected to the output termi nals marked and They are located at the lower right and lower left corners of the front panel The CV 500 I provides Twist Mate European weld cable con nector receptacles K852 Twist Mate European connector plugs are avail able for the cable size to be used The Export model includes two Twist Mate plugs for 2 0 3 0 70 95mm2 cable and S18737 installation instructions This informa tion is also located at the rear of this manual Output Cables CABLE SIZES FOR COMBINED LENGTH OF ELECTRODE AND WORK CABLE MACHINE LOAD 400A 500A 100 DUTY 50 DUTY CABLE LENGTHS CYCLE CYCLE UP TO 50 ft 3 0 2 0 15m 85 mm2 67 mm2 50 to 100 ft d 2 0 15 30 m 85 mm2 67 mm2 d 100 150 ft 30 46 m
17. 81 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
18. 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 amp Cutting ANSI Standard 749 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 available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE o d gs Th no scalding GEN the O oi radiator pressure cap when the engine is powered equipment hot 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires H to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes o outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts 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 ELECTRIC AND SR MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnet
19. IM481 B CV 500 February 2011 For use with machines Codes 10088 thru 10092 10277 10278 11356 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL AA E pe ISO 9001 Copyright Lincoln Global Inc LINCOLN e World s Leader in Welding and Cutting Products e Sales 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 SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS 4 Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR
20. PERVISOR 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 ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 0 E1 APDRERET EI AE F u RACE TIBELTTFEL KEE ECH 75 OF OR E fE Fi APR e Assal SWA e saxo SUIS witz HS Liz ELE MESHA a ye Lag do co all hia ya d a Jul Les gar cl Mail oe a sa y BeloHAle Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere co
21. S The three input lines are brought in through the rear panel of the power source and attached to the input contactor Removal of the removable access panel makes the contactor accessible for the input cable connections INPUT LINE VOLTAGE COMPENSATION The power source is equipped with input line voltage compensation as standard For a line voltage fluctua tion of 10 the output will remain essentially con stant This is accomplished through the feedback net work in the control 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 tions 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 MACHINE COOLING The fan pulls air in through the louvered front of the machine over the internal parts and exhausts out the louvered rear of the machine The fan motor is fully enclosed has sealed ball bearings requires no lubri cation and operates when the power switch is turned on CASE FEATURES The machine uses a 32 813mm long base The low profile case facilitates installation of the machine under a workbench and stacking the machines three high to conserve floor space The case front incorporates a recessed hinged control panel wher
22. alling or extending the wiring of a remote control Improper connection of this unit can lead to loss of control and or poor welding Only the green lead can and should be grounded to the machine case When extending the standard remote control make sure the leads are the same and the splice is waterproof Be very careful not to ground the cable when in use and don t let the lugs touch against the case OUTPUT VOLTAGE The open circuit voltage of the machine should be adjustable from 10 to 46 volts If any other condition exists refer to the Troubleshooting Guide FAULT PROTECTION OPERATION The overload protection circuit in the Control Board will limit the welding current heat to approximately 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 sides of the machine Board is mount ed on back of the case front 1 Visually inspect the Board for overheated compo nents or damaged components CHECKING OUTPUT CONTROL RHEOSTAT ON MACHINE Turn machine off CO position Remove the screws from the hinged control panel and open the panel Turn the Output Control switch to Remote Disconnect the harness plug from the Control PC Board With an ohmmeter on X1K connect it to lead 210 and 75 on R4 Exercise caution to avoid damaging rheostat tabs Rotate the O
23. an cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the corr
24. ce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause in
25. ce with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension
26. ctifier 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 TWIST MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS ELECTRIC SHOCK CAN KILL TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING PLUGS ON CABLES OR WHEN CONNECTING OR DISCONNECTING PLUGS TO WELDING POWER SOURCE 1 CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE APPROPRIATE CABLE SIZE PER TABLE BELOW AND SKIN CABLE JACKET TO LENGTH SPECIFIED AMERICAN EUROPEAN RANGE BOOT MARKING N EUROPEAN CABLE SKIN LENGTH 35 50 2 1 35 50 mm 1 INCH 25 4mm 50 70 1 0 2 0 50 70 mm 1 INCH 25 4mm 70 95 2 0 3 0 70 95 mm 1 5 INCH 38 1mm 2 If necessary trim cable end of boot at groove s to match cable diameter Boot must fit tightly enough to seal around outside diameter of cable NOTE Some boots are designed to accommodate different cable d
27. d settings Check and replace if defective Place switch in Local Check and replace if found faulty Check and replace if found faulty Check lead continuity and con nections for an open and repair if necessary Replace See Procedure for Replacing PC Boards Trouble Output control not functioning on Remote control Poor arc striking with semiautomatic or automatic wire feeders Poor arc characteristics Cause Output Control switch in wrong position Faulty Output Control switch Faulty remote control poten tiometer Leads or connections open in control circuit Faulty Control PC Board Poor work connection Improper procedures Defective Control PC Board Defective Control PC Board Capacitor s in output circuit failed A failure is indicated if the small vent plug on top of a capacitor is raised or blown out What To Do Place switch in Remote Check and replace if found faulty Check and replace if found faulty Check all leads and connections internal or remote for continuity repair if necessary Replace See Procedure for Replacing PC Boards Work connection must be ade quate for application Adjust procedures for improved starting Replace See Procedure for Replacing PC Boards Replace See Procedure for Replacing PC Boards Replace entire bank of capaci
28. e all the machine controls are mounted This recessed panel protects the controls and mini mizes the possibilities of accidental contact This con trol panel can be easily opened to permit access to the enclosed section which contains the terminal strips PC board etc The output lead terminals are also recessed to avoid any object or person acciden tally coming in contact with an output terminal The individual case sides are removable for easy access for internal service or inspection These are removable even though the machines are stacked three high The case rear top section is equipped with a remov able access panel This provides easy access to the input contactor easy connection and reconnection of input leads and easy access for service or inspection Although the machine is designed for use in rain sheltered environemnts the transformer and choke assembly are dipped in a special corrosion resistant epoxy paint A permanent lifting hook is located at the top of the machine and is positioned so that it acts as nearly as possible through the center of gravity This lift hook is so positioned that it fits without interference under the base of the second machine when stacking PARALLELING There are no provisions on the CV 500 I to permit par alleling DIODE OPTION Factory installed only The CV 500 I Diode option is required to utilize the cold start and cold electrode sensing features of the NA 3 NA 5 or NA 5R
29. ecommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment 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 posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation 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 a
30. ect shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located e Away from areas where they may be struck or subjected to physical damage e A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Pi Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordan
31. elding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover LE plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal SH FUMES AND GASES can be dangerous 5 a Welding may produ
32. energized when the POWER switch is in the 0 position The white light next to the POWER switch indicates when the input contactor is energized CONTROL SETTINGS amp DESCRIPTIONS OUTPUT VOLTAGE CONTROL DIAL The Output 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 welding The machine is equipped with line voltage compensa tion as a standard feature This will hold the output constant except at maximum output of the machine through a fluctuation of 10 input line voltage OUTPUT CONTROL LOCAL REMOTE SWITCH The Output Control toggle switch on the control panel labeled Local Remote gives the operator the option of controlling the output at the machine control panel or at a remote station For remote control the toggle switch is set in the Remote position and controlled at the wire feed unit control or by connecting a K775 control to terminals 75 76 and 77 on the terminal strip at the front of the machine or by connecting a K857 control with a K864 adapter to the 14 pin con nector on the front of the machine For control at the machine control panel Output Voltage control dial the toggle switch is set in the Local position Exception When used with an LN 9 LN 9 GMA or NA 5 wire feeder the Output Control switch must be in the Remote pos
33. enian niaior anaa 12 14 E UE Tee EE 15 We SUA AUN RS ER a a a oceans a cas 16 18 Safety PrECAUOMS EE 16 Ree 16 Application re e E 16 Ee le RE 16 Input Power Connections assisia d rege e laica 16 Output Cable Connections miis att 17 Installation of Field Installed Options ooooonccccnniconincconncccnnncccnnnnccnnnarnnranc crac 17 18 Installation of Equipment Required for Recommended Processes 18 Operating InStructi NS sssini iii ci n a litis 19 Safety LEE 19 Power Source Operati N sis ociosos nicol e didier ane dim rai dites talle 19 21 Re 19 Starting the MACHING sc E 19 Control Settings amp Descriptions 19 21 Oil e 21 Routine Maintenance send dee deeg dd gege deet deeg 21 Trouble NO EE 22 25 Procedure for Replacing P C Boards 26 Remote Control amp System Checks AAA 27 Twist Mate Welding Cable Plug Instructions 28 DIAG LE LR PEPA On EE beaten E T 29 30 Parts Pages 4 eee ae ed dede ne nier er ta P236 Series MEANINGS OF GRAPHIC SYMBOLS The CV 500 I nameplate has been designed to use international symbols in describing the function of the various components Below are the symbols used POWER ON OFF SWITCH lt vn e e rm zm gt Input Power rm rm rm On en rn mm gt Off OUTPUT CONTROL DIAL y Output Voltage Control Export Model DA meee Output Voltage Control European Model CIN Lies l O Increase Decrease of Output Voltage OUTPUT CONTROL LOCAL REMOTE
34. hed to the lead connecting the secondaries Both thermostats are connected in series with 2 4 circuit H the machine is overloaded the primary thermostat will open the output will be zero the amber thermal pro tection light will be on and the fan will continue to run The secondary thermostat will open either with an excessive overload or insufficient cooling The output will be zero the amber protection light will be on and 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 fault protection circuit This circuit senses an overload on the power source and limits the output to approxi mately 550 amps by phasing back the SCR s Protection is provided to protect the circuitry from accidental grounds If leads 75 76 or 77 are acciden tally grounded to the positive output lead the output will be reduced to a low value thus preventing any damage to the machine If the ground occurs between 75 76 77 and the negative output lead one of the PC board electronic self restoring fuses will blow pre venting any machine damage After the ground is cleared the fuses automatically reset within a few seconds MAINTENANCE N WARNING e ELECTRIC SHOCK can kill Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on e
35. iameters without trimming These boots do not have grooves at the cable end Soap or other non petroleum based lubricant will help to slide the boot over the cable 3 Slide rubber boot onto cable end BOOT 1 CABLE SEE ABOVE TRIM 4 Slide the copper tube into the brass plug SET SCREW 5 Insert cable into copper tube y 70 95 size may have 2 set screws BRASS PLUG COPPER TUBE 6 Tighten set screw s to collapse copper tube Screw s must apply firm pressure against welding cable The top of the set screw s will be nearly flush or below the surface of the brass plug after tightening 7 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle 9 20 91J S18737 RUBBER BOOT MARKED WITH 70 95 200 TIN PLATED 450 COPPER TUBE 2 SET SCREWS BR A N A DISPLACEMENT HOLE PERMISSIBLE N B RELATIONSHIP BETWEEN SET SCREWS AND RAISED TAB NOT IMPORTANT NOTES 9 20 91J M15479 1 221 O Gate leads plug to Control P C board P3 X POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD P5 220 204 222 X3 O O ANODE CATHODE O 223 G2 G3 X3 220 O O To side of capacitor bank D4 SHUNT 204 204 204 To plug P1 To T1 main transformer O DUAL amp SINGLE VOLTAGE UNDER 346 VOLTS SHOWN CONNECTED
36. ic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safet gege erat y A y minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on
37. ition or automatic shutdown of the LN 9 or NA 5 may occur POLARITY SELECTION Polarity selection is made by appropriately connecting the electrode and work welding cables to either the terminal or to the terminal Select Voltmeter switch for or electrode for the remote 21 work sensing lead VOLTMETER SWITCH Select for positive electrode or for negative electrode This switch selects electrode polarity for the remote 21 work sensing lead of automatic or semi automatic equipment THERMAL PROTECTION LIGHT The amber thermal protection light will be lit if either of the two protective thermostats have opened The out put power will be disabled but input power will still 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 at receptacle pins and K A 10 amp circuit breaker protects this circuit 115 VAC is available at receptacle pins A and J except on the European model A 10 amp circuit breaker protects this circuit Note that the 42 VAC and 115 VAC circuits are electrically isolated from each other FRONT VIEW OF 14 PIN CONNECTOR RECEPTACLE FUNCTION 115 VAC Export Model Only Chassis Connection Trigger Circuit Trigger Circuit Output Control Output Control Output Control Work Connection
38. jury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent 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 3 72 WELDING and CUTTING Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They c
39. lty Open in feedback circuitry Faulty Control PC Board Output control potentiometer cir cuit open Lead 75 One input fuse blown One phase of main transformer open Faulty Control PC Board Output control potentiometer defective Output control potentiometer Leads 210 211 or 75 open Input contactor contacts frozen Defective Power I O switch S1 Poor work or electrode connec tion Welding leads too small Welding current or voltage too low Defective main SCR bridge Output Control Local Remote switch S2 in wrong position Faulty Output Control switch Faulty Output Control potentiometer Leads or connections open in control circuit Faulty Control PC Board What To Do Check position of switch Check switch and replace if faulty Check wiring and control PC Board wiring harness plugs Replace See Procedure for Replacing PC Boards Check and replace potentiometer if faulty Check wiring of Lead 75 Check and replace if blown after checking for reason for blown fuse Check for open and repair Replace See Procedure for Replacing PC Boards Check and replace if faulty Check and repair broken leads Check and replace if necessary Replace Check and clean all connections Check table in instruction manual Check procedures for recom mende
40. m as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas XVFFYA H EAZAKCRUP DSR EFFERRI VY FE DEM2TFEU e HEMMER SHA AHS chat AL alll J il gS Jl abil o Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas removidas O IJI RJAL EEE TRREMFELEVTF V0 BERTA RAR LARA Ko ezo Yel dos sed HAS AREY culs 13 jall la gaii ve Aale Cut Ad dl Ayaa Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese ES BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR ESMERO 2 1 DETETE MA ETIEMLTF L LTRHOR MEI TR TE RA BAM PO D At E AE UR AO DA DIR AE RA IEA RIRA E dE A T R D O A BI A E R E RE o ol Hg SEA HYR SISMA HAY EYR Sas ETSAI SHC be aal call Zaff gl celalat 2 y yaaa d AA all oig BO guet illa ad y ouais L LINCOLN amp e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 4
41. mber is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet e For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it e For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below 44 WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Safety Precautions arcen a E A E A 2 5 INtFOGUGTONY laten 1 e e EE 7 Meaning of Graphic Symbols iii 8 11 General Machine Descrpti h ssrsnn eee era sl teo ratita 12 Recommended Processes amp Equipment 12 Desidn SUMMA EE 12 Operational Features amp Controls sssrini un
42. n Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e electro dos com a pele ou roupa molhada Isole se da pe a e terra o EPOT D NAHE TFPANKACTMNEWCE o MLMPT APSSAPEBRE ATUSHRELTFEL ET EE e CRA CRM ML eR ATAH SASS Je SA Ez BSS Bo 43x OMAR RAS AAS ASA OAR UE W us Gill la Quali Y dr i slay AS d Gil gl STE cl DE dan le die pg Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos ORA1PIVO EDORTORE ER GEXELTIAUEEA PIS MR T SRE LFB AT ends 248 YZ AIX Me dy Ole JA ALI Aal pu Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use prote o para a vista ouvido e corpo o B HRUSBICRBRELTE No OMRIR HRAEBSHRRAR ex 14 Sal save ASIHALL did y die de Lily ellen cil sai Sg Al KR A 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 SU
43. ny 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 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 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 Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code nu
44. om 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 Field Service Facility 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 TROUBLESHOOTING GUIDE Trouble Input contactor CR1 chatters Machine input contactor does not operate Machine input contactor operates but no output when trying to weld Machine has minimum output and no control Machine has high output and no control Cause Faulty input contactor CR1 Low line voltage Supply line fuse blown Contactor power circuit dead Broken power lead Wrong input voltage Open input contactor coil POWER 1 0 switch S1 not closing Circuit between 2 C and 4 D is not being closed Electrode or work lead loose or broken Open main transformer T1 pri mary or secondary circuit Defective Control PC Board Primary or secondary ther mostats open Terminals 75 76 or 77 grounded to positive output Terminals 75 76 or 77 grounded
45. on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux r
46. quipment e Do not touch electrically hot parts Routine Maintenance 1 The fan motor has sealed bearings which require no service In extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the machine at regular intervals In extremely dusty locations dirt may accumulate on the remote control terminal strip Wipe or blow this terminal strip off at regular intervals This is particularly important in damp locations TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed 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 throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may 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 sympt
47. quipped to furnish nominally 115 volt AC and 42 volt AC auxiliary power for operat ing wire feeding equipment etc The auxiliary power is available at the 14 pin MS style connector recepta cle on the control panel and or at a terminal strip behind the hinged control panel on the front of the power source 115V AC is available at receptacle pins A and J except on European model and termi nals 31 and 32 42V AC is available only at recepta cle pins and K The 115V AC and the 42V AC are isolated circuits and each is protected by a 10 amp circuit breaker REMOTE CONTROL CONNECTIONS Remote control connections are available both at a 14 pin connector receptacle located on the control panel and on terminal strips with screw connections located behind the hinged control panel on the front of the power source WATER COOLER CONNECTOR A Continental European receptacle 220V Schuko type is located on the rear panel for supplying 220VAC to a water cooler 2 amp circuit breaker which is also located on the rear panel protects this circuit OUTPUT CONNECTIONS The output terminals are recessed on the case front and labeled and The CV 500 I provides Twist Mate European connector receptacles K852 Twist Mate European connector plugs are avail able for the cable size to be used The Export model includes two Twist Mate plugs for 2 0 3 0 70 95mm cable and S18737 installation instructions INPUT CONNECTION
48. s RECOMMENDED PROCESSES amp EQUIPMENT The CV 500 I is supplied as a constant voltage power source only It is designed for all Innershield Outershield and all solid wire and gas procedures within the capacity of the machine The output char acteristics have been optimized for these CV process es without use of a variable arc control The CV 500 I is designed to be used with the LN 7 LN 7 GMA LN 8 LN 9 LN 9 GMA LN 22 LN 23P LN 25 or LN 742 semiautomatic wire feed ers the NA 3 NA 5 and NA 5R automatics within the capacity of the machine The CV 500 I Diode option is required to utilize the cold start and cold elec trode sensing features of the NA 3 NA 5 and NA 5R The 14 pin receptacle of the European model does not provide 115 VAC for these feeders Use K350 Adapter Kit DESIGN SUMMARY Operational Features amp Controls ARC CHARACTERISTICS Through the unique combination of the transformer three phase semiconverter rectifier capacitor bank and output choke design in conjunction with the solid state control system an outstanding constant voltage welding performance 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 10 MACHINE OUTPUT CONTROL SWITCH LOCAL OR REMOTE The machine output voltage can be controlled by either
49. stack more than three high e Do not stack the CV 500 I on top of any other machine The units may be stacked three high by observing the following safety precautions 1 Make sure the first or bottom unit is setting on a level well supported surface 2 The units must be stacked with their fronts flush making sure the two holes in the base rails of the unit being stacked on top are over the two holes located on the top front corners of the unit it is being stacked on Fasten the units together with 5 16 bolts nuts and lockwashers through these holes 3 Remove fastening bolts before lifting unit off stacks Input Power Connections By removing the rear access panel the three phase input power is connected to the three line terminals on the input contactor and the earth grounding lead to the grounding terminal on the input box floor marked with the Le Install the reconnect panel jumper links for the proper input voltage per the diagram pasted inside the access panel cover See Installation Data below INSTALLATION DATA Input Rating Recommended input wire and fuse sizes for maximum rated output In addition follow latest National Electrical Code and Local Code Nameplate Input Wire Size Amperes Type 75 C Copper Wire Size Copper Conductors AWG on Conductors in Conduit AWG Minimum Grounding BUSSMANN SUPER LAG ire Si FUSE SIZE AND CATALOG NUMBER FUSE SIZE CATALOG NUMBER
50. t two cases replace rheostat Check cable for any physical damage POWER RECTIFIER BRIDGE ASSEMBLY CHECKING PROCEDURE WARNING KR ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts 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 SCR s 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 SCR s 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 Re
51. tors Do not replace individual capacitors WARNING The liquid electrolyte in these capacitors is toxic Avoid contact with any portion of your body Clean up vented electrolyte using rubber gloves and a water dampened cloth Any electrolyte which gets on skin clean with soap and water Procedure for Replacing PC Boards WARNING e ELECTRIC SHOCK can kill e Have an electrician install and service this equipment e Turn the input power off at the fuse box before working on equipment e Do not touch electrically hot parts When a PC board is suspected to be defective the following procedure must be followed 1 Visually inspect the PC board If the board has fuses check to see if any are blown Are any of the components damaged ls a conductor on the back side of the board damaged If electrical dam age is visible on the PC board inspect the machine wiring for grounds or shorts to avoid damaging a new PC board Install a new PC board only after a visual inspection of the PC board and machine wiring is satisfactory 2 If the problem is remedied by a new PC board install the old PC board and see if the problem still exists If the problem does not return with the old board a Check the PC board harness plug and PC board plug for contamination corrosion or oversize b Check leads in the harness for loose connec tions CONNECTING THE REMOTE CONTROL TO THE MACHINE Extreme caution must be observed when inst
52. utput control rheostat The resistance reading should be from around zero to 10K ohms Check the resistance reading between 77 and 75 on the terminal strip The reading must be 10K ohms No reading will indicate an open rheostat and a low read ing will indicate a shorted or partially shorted rheostat in either case replace POWER 1 0 SWITCH CHECK 1 Turn off the machine input power CO position S1 has 115 volts across it when the input power is connected 2 Isolate the switch to be tested by removing all con necting leads 3 Check to make sure the switch is making open and closed connections with a V O M meter Put ohmmeter on X1 scale The meter should read zero resistance with switch Il and infinite with switch 0 4 Put the ohmmeter on X1K scale and measure the resistance between the terminal and the case of the machine touch a self tapping screw Reading should be infinite 5 If either step 3 or step 4 fails replace the switch 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 las
53. your right side SY A Connect the work cable to the workpiece as close as possible to the area being welded 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 as appropriate Do not work next to welding power source SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do nat touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment e Semiautomatic DC Constant Voltage Wire Welder e DC Manual Stick Welder e AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic w
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