Lincoln IDEALARC CV 420, IDEALARC CV 505 Operator's Manual

IDEALARC CV 420 & CV 505

OPERATOR’S MANUAL

MANUALE OPERATIVO

BEDIENUNGSANLEITUNG

MANUAL DE INSTRUCCIONES

MANUEL D'UTILISATION

BRUKSANVISNING OG DELELISTE

GEBRUIKSAANWIJZING

BRUKSANVISNING

INSTRUKCJA OBSŁUGI

IM3027

02/2011

Rev. 1

KÄYTTÖOHJE

MANUAL DE INSTRUÇÕES

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

www.lincolnelectric.eu

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

IDEALARC CV 420
IDEALARC CV 505

conforms to the following directives:

2006/95/CEE, 2004/108/CEE

and has been designed in compliance with the

following standards:

EN 60974-1, EN 60974-10

(2005)

Paweł Lipiński

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

12/05

English EnglishI

12/05

THANKS! For having choosen the QUALITY of the Lincoln Electric products.
 Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

 For future reference record in the table below your equipment identification information. Model Name, Code &

Serial Number can be found on the machine rating plate.

Model Name:

………………...…………………………….…………………………………………………………………………………………..

Code & Serial number:

………………….……………………………………………….. …………………………………………………….……………..

Date & Where Purchased:

…………………………………………………………………... ……………………….…………………………………………..

ENGLISH INDEX

Safety ..............................................................................................................................................................................1

Installation and Operator Instructions..............................................................................................................................2

Electromagnetic Compatibility (EMC)..............................................................................................................................4

Technical Specifications..................................................................................................................................................5

WEEE..............................................................................................................................................................................5

Spare Parts......................................................................................................................................................................6

Electrical Schematic ........................................................................................................................................................6

Accessories.....................................................................................................................................................................6

English EnglishII

Safety

11/04

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repa ir
procedures are performed only by qualified person. Read and understan d this manual before operating this equipm ent.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not respo nsible
for damages caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician bef ore operating this
equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: Use a shield with the proper filter and cover plates to protect your eyes from
sparks and the rays of the arc when welding or observing. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on an y
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.

English English1

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the
correct shielding gas for the process used and properly operating regulators design ed for the gas and
pressure used. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.

Installation and Operator Instructions

Read this entire section before installation or operation
of the machine.

Location and Environment

This machine will operate in harsh environments.
However, it is important that simple preventative
measures are followed to assure long life and reliable
operation:

 Do not place or operate this machine on a surface

with an incline greater than 15° from horizontal.

 Do not use this machine for pipe thawing.
 This machine must be located where there is free

circulation of clean air without restrictions for air
movement to and from the air vents. Do not cover
the machine with paper, cloth or rags when
switched on.

 Dirt and dust that can be drawn into the machine

should be kept to a minimum.

 This machine has a protection rating of IP23. Keep

it dry when possible and do not place it on wet
ground or in puddles.

 Locate the machine away from radio controlled

machinery. Normal operation may adversely affect
the operation of nearby radio controlled machinery,
which may result in injury or equipment damage.
Read the section on electromagnetic compatibility in
this manual.

 Do not operate in areas with an ambient

temperature greater than 40°C.

Duty cycle and Overheating

The duty cycle of a welding machine is the percentage of
time in a 10 minute cycle at which the welder can
operate the machine at rated welding current.

Example: 60% duty cycle:

protected according to appropriate rules.
Check the input voltage, phase, and frequency supplied

to this machine before turning it on. Verify the
connection of grounding wires from the machine to the
input source. The allowable input voltages are 3x230V
and 3x400V 50Hz (400V: factory default). For more
information about input supply refer to the technical
specification section of this manual and to the rating
plate of the machine.

If it is necessary to change the input voltage:
 The input cable must be disconnected from the

mains supply and the machine switched OFF.

 Remove the big side cover from the machine.
 Reconnect X6 according to the diagram below.

 Replace the big side cover.

Make sure that the amount of mains power available
from the input supply (connection) is adequate for
normal operation of the machine. The necessary
delayed fuse (or circuit breaker with "D" characteristic)
and cable sizes are indicated in the technical
specification section of this manual.

Refer to points [1] and [11] of the images below.

Output Connections

Refer to points [4], [5], [6] and [8] of the images below.

Controls and Operational Features

Welding for 6 minutes. Break for 4 minutes.

Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.

Minutes or decrease

duty cycle

Input Supply Connection

Installation and mains outlet socket shall be made and

English English2

1. Power Switch ON/OFF (O/I): It controls the
machine power input. Be sure the power source is
connected to the mains supply before turning power
on ("I").

2. Power Indicator Light: It indicates that the power is
on.

3. Thermal Indicator Light: It indicates that the
machine is overloaded or that the cooling is not
sufficient.

4. Low Inductance Negative Output Socket: The low
inductance connection is typically used for short arc
welding of mild steel, particularly on thin materials or
when using CO

shielding gas.

2

5. High Inductance Negative Output Socket: The high
inductance connection is more suitable for short arc
welding in heavier work or when using 75% Argon /
25% CO2 shielding gas. The connection produces a
softer arc and a flatter bead with more wash-in than
the low inductance connection. Spray type transfer
is possible with either connection.

9. Covered Hole: For CO2 gas heater socket (see
accessories, K14009-1 CO2 Socket Kit).

10. Fuse: This fuse protects the wire feeder supply
circuit (see Spare Parts).

6. Wire Feeder Receptacle: 14-pins receptacle for
wire feeder. Provides connections for auxiliary
power of wire feeder.

7. Wire Feeder Voltmeter Switch: This switch selects
the polarity of the wire feeder voltmeter, if so
equipped. When the welding torch is positive (MIG,
Outershield and some Innershield processes), set
the switch to "+". When the welding torch is
negative (most Innershield applications), set the
switch to "-".

8. Positive Output Socket: Allows the connection, with
the power cable, to the wire feeder.

11. Power Input Cable: Connect the proper plug to the
input cable then into the rated output according to
appropriate rules. Only qualified personnel shall
connect this plug.

12. Cooler Power Supply Socket (For water cooled
model only): For supplying the cooler unit. The
socket has an output of 230V, 2.5A and is protected
by the circuit breaker [13].

13. Circuit Breaker (For water cooled model only):
Protects the Cooler Power Supply socket [12]. It
shuts off the power supply when the current
exceeds 2.5A. Press it to restore the power supply.

14. Cooler (For water cooled model only): It refrigerates
the water cooled welding torch. The cooler works
continuously.

WARNING

Read and understand the cooler manual before
connecting it to the machine.

15. AV-meters: Available as a kit K14097-1.

Welding Cables Connections

Insert the plug of the work cable into the socket [4] or [5].
The other end of this cable connects to the work piece
with the work clamp.

English English3

Connect the wire feeder LINC FEED 33 to the power
source:

 insert the positive welding cable into the output

socket [8].

 insert the wire feeder control cable into the

socket [6] (see Accessories,

cable K10347-PG-xM or K10347-PGW-xM)

Source/wire feeder

.

Use the shortest possible cable lengths.

Machine and Circuit Protection

The CV420 / CV505 is protected against overheating,
overload and accidental short-circuits.

If the machine is overheated, the thermal protection
circuit will decrease the output current to 0. The thermal
protection indicator [3] will turn on. The thermal
protection circuit will turn on the output current again,
when the machine is cooled.

The CV420 / CV505 is also electronically protected
against overload and accidental short-circuit. The
overload and short-circuit protection circuit automatically
reduces the output current to a safe value when it
detects an overload.

necessary.

 Check condition and operation of the cooling fan.

Keep clean its airflow slots.

Periodic maintenance (every 200 working hours
but at list once every year)

Perform the routine maintenance and, in addition:
 Keep the machine clean. Using a dry (and low

pressure) airflow, remove the dust from the external
case and from the cabinet inside.

 Check and tighten all screws.

WARNING

Mains supply network must be disconnected from the
machine before each maintenance and service. After
each repair, perform proper tests to ensure safety.

Maintenance

WARNING

For any maintenance or repair operations it is
recommended to contact the nearest Technical Service
Center or Lincoln Electric. Maintenance or repairs
performed by unauthorized service centers or personnel
will null and void the manufacturer's warranty.

The frequency of the maintenance operations may vary
in accordance with the working environment where the
machine is placed.

Any noticeable damage should be reported immediately.

Routine maintenance (everyday)

 Check cables and connections integrity. Replace, if

necessary.

 Remove the spatters from the welding gun nozzle.

Spatters could interfere with the shielding gas flow
to the arc.

 Check the welding gun condition: replace it, if

Transport

WARNING

To ensure safety transport it is necessary to:
 Lift only power source without gas cylinder, cooler

and wire feeder.

 Screw down an eye bolt and apply load axially in 45

degree angle in accordance to the drawing.

 Ensure equal length of lifting lines.

Electromagnetic Compatibility (EMC)

This machine has been designed in accordance with all releva nt directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.

11/04

This machine has been designed to operate in an industrial area. To operate in a domestic area it is
necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The
operator must install and operate this equipment as described in this manual. If any electromagnetic
disturbances are detected the operator must put in place corrective actions to eliminate these disturba nces

with, if necessary, assistance from Lincoln Electric.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.
 Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

machine.

 Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
 Safety and control equipment for industrial processes. Equipment for calibration and measurement.
 Personal medical devices like pacemakers and hearing aids.
 Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure

that all equipment in the area is compatible. This may require additional protection measures.

 The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.
 Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

English English4

 The output cables should be kept as short as possible and should be positioned together. If possible connect the

work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipme nt.

 Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

WARNING

The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those
locations, due to conducted as well as radiated disturbances.

WARNING

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to
7,76MVA for CV 420 and 9,95MVA for CV 505 at the interface point between the user’s supply and the public system. It
is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network
operator if necessary, that the equipment is connected only to a supply with a short circuit power Ssc greater than or
equal to 7,76MVA (CV 420) and 9,95MVA (CV 505).

Technical Specifications

IDEALARC CV 420 & CV 505

INPUT

Input Voltage

230 / 400V  10%

Three Phase

Duty Cycle

Based on a 10 min. period)

(

420:

60%

100%

Input Power at Rated Output EMC Group / Class

420:
505:

RATED OUTPUT AT 40°C

22kVA @ 60% Duty Cycle II / A
29kVA @ 60% Duty Cycle II / A

Output Current Output Voltage

420A
325A

Frequency

50 Hz

35.0 Vdc

30.3 Vdc

505:

420:
505:

420:

505:

420 (water version):

505 (water version):

WEEE

English

60%

100%

Welding Current Range Maximum Open Circuit Voltage

30A - 420A
40A - 500A

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or Circuit Breaker Size Input Power Cable

63A (for 230V) Superlag
32A (for 400V) Superlag

63A (for 230V) Superlag
32A (for 400V) Superlag

PHYSICAL DIMENSIONS

Height Width Length Weight

420:

505:

Operating Temperature

-10°C to +40°C

Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment an d human health!

870 mm
870 mm

870 mm
870 mm

500A
385A

OUTPUT RANGE

420:
505:

420:

505:

565 mm
700 mm

565 mm
700 mm

39.0 Vdc

33.3 Vdc

43 Vdc
48 Vdc

4 Conductor, 6mm

4 Conductor, 10mm

1030 mm
1030 mm

1030 mm
1030 mm

Storage Temperature

-25°C to +55°C

2

2

139 kg
165 kg

147 kg
173 kg

07/06

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Spare Parts

12/05

Part List reading instructions

 Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service

Department for any code number not listed.

 Use the illustration of assembly page and the table below to determine where the part is located for your particular

code machine.

 Use only the parts marked "X" in the column under the heading number called for in the assembly page (# indicate

a change in this printing).

First, read the Part List reading instructions above, then refer to the "Spare Part" manual supplied with the machin e, that
contains a picture-descriptive part number cross-reference.

Electrical Schematic

Refer to the "Spare Part" manual supplied with the machine.

Accessories

K10347-PG-xxM Source/wire feeder cable (gas). Available in 5, 10 or 15m.
K10347-PGW-xxM Source/wire feeder cable (gas and water). Available in 5, 10 or 15m.
K14009-1 CO2 Socket Kit.
K14097-1 AV Meter kit.

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