Lincoln Electric CV-300 User Manual

IDEALARC CV-300

SERVICE MANUAL

SVM116-A

March 1999

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind.Howev er , your
overall safety can be increased
by proper installation ... and
thoughtful operation on your part.
DO NOT INSTALL, OPERATE
OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MAN­UAL AND THE SAFETY PRE­CAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.

For use with machines having Code Numbers:

9456,
9486,
9520,
9939,
9940,

10180,

10181.

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• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

i

SAFETY

i

WARNING

ARC WELDING can be hazardous.

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN
AWAY. PACEMAKER 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 W elding 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 THA T ALLINSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PER­FORMED ONLY BY QUALIFIED INDIVIDUALS.

ELECTRIC SHOCK can kill.

1.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

1.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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

1.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

1.d. 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.

1.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

1.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

1.g. Never dip the electrode in water for cooling.

1.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.

1.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

1.j. Also see Items 4.c. and 6.

2.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

2.c. 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.

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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

3.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

3.d. 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.

ARC RAYS can burn.

2.a. 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
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

FUMES AND GASES
can be dangerous.

3.a.Welding may produce 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

vapors

to

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3.e. Also see item 7b.

IDEALARC CV-300

Apr. ’93

ii

SAFETY

ii

WELDING SPARKS can
cause fire or explosion.

4.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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.

4.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 Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

4.c. 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.

4.d. 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 can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

4.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

4.f.

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.

4.g. 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 circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

4.h. Also see item 7c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

5.a. Use only compressed gas cylinders
containing the correct 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.

5.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

5.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

5.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

5.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

5.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

5.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“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.

6.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

6.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

6.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

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Feb. ’95

IDEALARC CV-300

iii

SAFETY

iii

FOR ENGINE
powered equipment.

7.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

7.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

7.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 vaporizing 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.

____________________________________________________

7.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.

ELECTRIC AND MAG­NETIC FIELDS
may be dangerous

8.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

8.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

8.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

8d. All welders should use the following procedures in order to

minimize exposure to EMF fields from the welding circuit:

8.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

8.d.2. Never coil the electrode lead around your body.

8.d.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 your right side.

8.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

8.d.5. Do not work next to welding power source.

____________________________________________________

7.e. In some cases it may be necessary to remove safety
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.

7.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.

7.g. 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.

___________________________________________________

7.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

Mar. ’93

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IDEALARC CV-300

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour

votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

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

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PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ’93

IDEALARC CV-300

RETURN TO MAIN INDEX

TABLE OF CONTENTS

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i - v

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Select Proper Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Input Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Reconnect Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Connect Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Installation of Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Installation of Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Twist-Mate Cable Plug Installation Instructions . . . . . . . . . . . . . . . . . . . .A-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Processes and Equipment . . . . . . . . . . . . . . . . . . . . . . .B-2

Machine Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Operating Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Machine and Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

vv

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Connecting Wire Feeder to the CV-300 . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Connecting Remote Control (K857) to CV-300 . . . . . . . . . . . . . . . . . . . .C-2

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Power Supply Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Protection Devices and Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

How to use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Diagnostic Routines and Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . .F-10

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22

Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-28

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-271

IDEALARC CV-300

INSTALLATION

TABLE OF CONTENTS

- INSTALLATION SECTION -

INSTALLATION SECTION ........................................ Section A

Technical Specifications ...................................................A-1

Safety Precautions...........................................................A-2

Select Proper Location.....................................................A-2

Stacking.......................................................................A-2

Tilting...........................................................................A-2

Input Electrical Connections.............................................A-3

Fuse and Wire Sizes...................................................A-3

Reconnect Procedure.......................................................A-4

Connect Output Cables....................................................A-7

Paralleling ....................................................................A-7

Installation of Field Installed Accessories........................A-7

Installation of Wire Feeders .............................................A-7

Twist-Mate Cable Plug Installation Instructions...............A-7

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IDEALARC CV-300

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - IDEALARC CV-300

INPUT - THREE PHASE/ 50-60 HERTZ ONLY

Standard Voltages Input Current at Rated Output

208/230/460/3/60 66/60/30 Amps
230/460/575/3/60 60/30/24 Amps

RATED OUTPUT

Duty Cycle Amps Volts at Rated Amps

CV-300 100% 300A 32

60% 400A 36

OUTPUT

Current Range Maximum Open Circuit Voltage Auxiliary Power

50A - 400A 55V 115 VAC, 5AMPS

42 VDC, 10AMPS

A-1

RECOMMENDED INPUT WIRE & FUSE SIZE

Input Voltage/ Fuse (Superlag) Type 750C wire in Type 750C Copper

Frequency or Breaker Size Copper conduit AWG Ground Wire in Conduit

(IEC Sizes)

208/60 100 4 (25mm2) 6 (16mm2)
230/60 100 4 (25mm2) 8 (10mm2)
460/60 50 10 (6mm2) 10 (6mm2)

575/60 40 10 (6mm2) 10 (6mm2)
200/50/60 100 4 (25mm2) 6 (16mm2)
220/50/60 100 4 (25mm2) 8 (10mm2)
230/50/60 100 4 (25mm2) 8 (10mm2)
380/50/60 70 8 (10mm2) 8 (10mm2)
400/50/60 50 8 (10mm2) 10 (6mm2)
415/50/60 50 8 (10mm2) 10 (6mm2)
440/50/60 50 10 (6mm2) 10 (6mm2)
500/50/60 50 10 (6mm2) 10 (6mm2)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH LIFT HOOK WEIGHT

ADD

21.5” 19.5” 27.0” 3.12” 300 lbs.

(546mm) (495mm) (686mm) (80mm) (136 Kg.)

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IDEALARC CV-300

A-2

INSTALLATION

A-2

Read entire Installation Section before installing
the IDEALARC CV-300.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
install this machine.

• Turn the input power OFF at the dis­connect switch or fuse box before
working on the equipment.

• Turn the Power switch on the CV-300 “OFF”
before connecting or disconnecting output
cables, wire feeder or remote connections, or
other equipment.

• Do not touch electrically hot parts.

• Always connect the IDEALARC CV-300 ground­ing terminal (located on the welder base near
the reconnect panel) to a good electrical earth
ground.

____________________________________

Follow these guidelines when stacking:

1. Select a firm, level surface capable of supporting
the total weight of up to three machines.

2. Set the bottom machine in place.

3. Stack the second machine on top of it by aligning
the two holes in the base rails of the second
machine with the two pins on top of the bottom
machine.

4. Repeat process for third machine.

NOTE: The machines must be stacked with the Case
Front of each machine flush with each other. See
Figure A.1.

STACKING HOLE

SELECT PROPER LOCATION

The IDEALARC CV-300 can be used indoors or out­doors. It has an IP-23 degree of protection.

Place the IDEALARC CV-300 where clean, cooling air
can freely circulate in through the side louvers and out
through the rear louvers. Dirt, dust, or any foreign
material that can be drawn into the machine should be
kept at a minimum. Not following these precautions
can result in the nuisance shutdown of the machine
because of excessive operating temperatures.

STACKING

Three IDEALARC CV-300 machines can be stacked.
DO NOT stack more than three machines in one

grouping.
DO NOT stack the IDEALARC CV -300 on another type

of machine.

STACKING PIN

FIGURE A.1 - Stacking IDEALARC CV-300
machines.

TILTING

The IDEALARC CV-300 must be placed on a stable,
level surface so it will not topple over. Do not place the
machine on an incline.

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IDEALARC CV-300

A-3

INSTALLATION

INPUT ELECTRICAL CONNECTIONS

WARNING

All input power must be electrically
disconnected before proceeding.

____________________________________

A-3

CASE BACK

RIGHT CASE
SIDE PANEL
(REMOVED)

1. Before starting the installation, check with the local
power company to determine if there is any ques­tion about whether your power supply is adequate
for the voltage, amperes, phase, and frequency
specified on the welder nameplate. Have a quali­fied electrician connect the input leads to L1, L2,
and L3 on the input reconnect panel in compliance
with the National Electrical Code, all local codes,
and the connection diagram located on the inside
of the Right Case Side Panel. This welder can
operate on a three-phase AC voltage supply only.

2. Models that have multiple input voltages specified
on the nameplate (e.g., 208/230) are shipped con­nected for the highest voltage. If the welder is to
be operated at a lower voltage, it must be recon­nected according to the instructions on the inside
of the removable Right Case Side Panel. See the
Reconnect Section of this manual for details on
reconnecting the machine to operate at different
voltages.

3. Be sure the voltage, phase, and frequency of the
input power is as specified on the machine rating
plate. See Figure A.2 for the location of the
machine's input cord entry and Reconnect Panel.

4. Access to the input reconnect panel is achieved by
removing the Right Case Side Panel of the CV-300
on the ON/OFF POWER SWITCH side of the
machine.

5. The frame of the welder must be grounded. A
ground terminal marked with the symbol ( ) is
located at the bottom of the input box to ground the
welder. See the National Electrical Code for
details on proper grounding methods.

ECONNECT
ANEL

INPUT CABLE
& CABLE CLAMP

FIGURE A.2 - Input Power Cable Entry Connections
and Reconnect Panel location.

FUSE AND WIRE SIZES

Protect the input circuit with the super lag fuses or
delay type circuit breakers listed on the

Specifications

being used. Delay type circuit breakers may be used.
The tripping action of delay type circuit breakers
decreases as the magnitude of the current increases.
They are also called inverse time or thermal/magnetic
circuit breakers.

DO NOT use fuses or circuit breakers with a lower amp
rating than recommended. This can result in "nui­sance" tripping caused by inrush current even when
machine is not being used for welding at high output
currents.

Use input and grounding wire sizes that meet local
electrical codes or see the
page in this manual.

page of this manual for the machine

Technical Specifications

Technical

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IDEALARC CV-300

A-4

INSTALLATION

RECONNECT PROCEDURE

Multiple voltage machines are shipped connected to
the highest input voltage listed on the machine's rating
plate. Before installing the machine, check that the
Reconnect Panel is connected for the proper voltage.

CAUTION

Failure to follow these instructions can cause
immediate failure of components within the
machine.

____________________________________

To reconnect a dual or triple voltage machine to a dif­ferent voltage, change the position of the leads or links
on the Reconnect Panel based the type of machine.
Follow The Input Supply Connection Diagram located
on the inside of the Right Case Side Panel.

A-4

For dual voltage machines, see Figure A.3.
For 208/230/440 voltage machines, see Figure A.4.
For 230/460/575 voltage machines, see Figure A.5.

CONNECTION FOR
UNDER 300 VOLTS

INPUT LINES

L3

L2

L1

GROUND

CONNECTION FOR
OVER 300 VOLTS

INPUT LINES

L3

L2

L1

GROUND

1. Check nuts on terminal board for tightness,
then place the five copper links in the posi­tions shown. Secure the links tightly with
the nine hex nuts provided.

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground ter­minal per National Electrical Code.

1. Check nuts on terminal board for tightness,
then place the copper links in the positions
shown. Double up the extra links in two of
the positions to save the extra links for
future use. Secure the links tightly with the
six hex nuts provided, then secure the
remaining three hex nuts in place for future
use.

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground ter­minal per National Electrical Code.

FIGURE A.3 - Reconnect Diagram For Dual Voltage Machines.

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IDEALARC CV-300

A-5

INSTALLATION

CONNECTION FOR
460 VOLTS 60HZ.

A-5

1. Check nuts on terminal board for tight­ness, then place the copper links in the
positions shown. Double up the links in
two of the positions to save them for
future use. Secure the links tightly with
the hex nuts provided. Secure the
remaining hex nuts in place for future
use.

uv w

uv w

L3

L3

INPUT LINES

L2

L1

GROUND

CONNECTION FOR
230 VOLTS 60HZ.

INPUT LINES

L2

L1

GROUND

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground ter­minal per National Electrical Code.

1. Check nuts on terminal board for tight­ness, then place the copper links in the
positions shown. Secure the links tight­ly with the hex nuts provided.

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground
terminal per National Electrical Code.

FIGURE A.4 - Reconnect Diagram For 208/230/440 voltage machines.

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uv w

L3

CONNECTION FOR
208 VOLTS 60HZ.

INPUT LINES

L2

L1

GROUND

IDEALARC CV-300

1. Check nuts on terminal board for tight­ness, then place the copper links in the
positions shown. Secure the links tightly
with the hex nuts provided.

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground
terminal per National Electrical Code.

A-6

INSTALLATION

CONNECTION FOR
575 VOLTS 60HZ.

A-6

1. Check nuts on terminal board for tight­ness, then place the copper links in the
positions shown. Double up the links in
two of the positions to save them for future
use. Secure the links tightly with the hex
nuts provided. Secure the remaining hex
nuts in place for future use.

uv w

uv w

L3

L3

INPUT LINES

L2

L1

GROUND

CONNECTION FOR
460 VOLTS 60HZ.

INPUT LINES

L2

L1

GROUND

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground ter­minal per National Electrical Code.

1. Check nuts on terminal board for tight­ness, then place the copper links in the
positions shown. Double up the links in
two of the positions to save them for future
use. Secure the links tightly with the hex
nuts provided. Secure the remaining hex
nuts in place for future use.

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground ter­minal per National Electrical Code.

FIGURE A.5 - Reconnect Diagram for 230/460/575 voltage machines.

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uv w

L3

CONNECTION FOR
230 VOLTS 60HZ.

INPUT LINES

L2

L1

GROUND

IDEALARC CV-300

1. Check nuts on terminal board for tight­ness, then place the copper links in the
positions shown. Secure the links tightly
with the hex nuts provided.

2. Connect L1, L2, & L3 as shown.

3. Connect terminal marked to ground ter­minal per National Electrical Code.

A-7

INSTALLATION

A-7

CONNECT OUTPUT CABLES

WARNING

ELECTRIC SHOCK CAN KILL.

TURN THE POWER SWITCH ON THE
CV-300 OFF BEFORE MAKING CON­NECTIONS TO THE OUTPUT TERMI­NALS OR WIRE FEEDER RECEPTA­CLE.

____________________________________

Note: Output cables must have Magnum Twist-Mate
plugs for connection to the CV-300. Order K852-95
Magnum Twist-Mate plugs (2 required) for connecting
2/0-3/0 (70-95 mm2) cables. Order K852-95 for con­necting 2/0-3/0 (70-95 mm2) cables. Refer to

Mate Cable Plug Installation Instructions

this manual.

1. Connect the positive output lead to the terminal
marked (+).

2. Connect the negative output lead to either the low
inductance terminal marked ( ) or the high induc­tance terminal marked ( ).

Note: Use the proper cable sizes for the work and elec­trode cables as shown in the following table.

CABLE SIZES FOR COMBINED LENGTHS OF COP­PER ELECTRODE AND WORK CABLE

Twist-

section of

INSTALLATION OF WIRE FEEDERS

Follow the instructions for the wire feeder that will be
used. See the

Accessories

section of this manual.

TWIST-MATE CABLE PLUG
INSTALLATION INSTRUCTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

TURN THE POWER SWITCH OF THE
WELDING POWER “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 strip
the cable jacket to length specified:

American

Boot Marking

35-50
50-70
70-95

(Metric)

Range Cable

Size

#2-#1 (35-50mm2)
1/0-2/0(50-70mm2)
2/0-3/0(70-95mm2)

Cable Skin

Length

1 inch (25.4mm)
1 inch (25.4mm)

1.5 inch (38.1mm)

Machine Size

300/100%
(400/60%)

PARALLELING

The CV-300 is not designed to be paralleled with any
other power source.

INSTALLATION OF FIELD
INSTALLED ACCESSORIES

For installation of compatible field installed acces­sories, refer to the instructions included with those
accessories.

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Lengths up to

150 Ft.

2/0 (70mm2)

Lengths from
150 to 200 Ft.

3/0 (95mm2)

IDEALARC CV-300

2. If necessary, trim the cable end of the boot at
groove(s) to match the cable diameter. See Figure
A.6. Boot must fit tightly enough to seal around
outside diameter of cable.

NOTE: Some boots are designed to accommodate dif­ferent cable diameters 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 the rubber boot onto cable end. See Figure
A.6.

4. Slide the copper tube into the brass plug. See
Figure A.6.

5. Insert cable into the copper tube. See Figure A.6.

A-8

INSTALLATION

6. Tighten the set screw(s) to collapse the tube. The
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.

BOOT

WELDING CABLE

SEE

ABOVE

TRIM

SET SCREW
(70-95 SIZE MAY HAVE
2 SET SCREWS)

A-8

COPPER TUBE

BRASS PLUG

FIGURE A.6 - Installing Twist-Mate Cable Plug.

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IDEALARC CV-300

NOTES

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IDEALARC CV-300

OPERATION

TABLE OF CONTENTS

- OPERATION SECTION -

OPERATION SECTION ............................................ Section B

Safety Instructions ............................................................B-1

General Description..........................................................B-1

Recommended Processes and Equipment ......................B-2

Machine Capability...........................................................B-2

Limitations........................................................................B-2

Controls and Settings.......................................................B-3

Power Switch...............................................................B-3

Wire Feeder Voltmeter Switch.....................................B-3

Local/Remote Switch...................................................B-3

Voltage Adjustment Control Knob ...............................B-3

115-Volt Circuit Breaker...............................................B-4

42-Volt Circuit Breaker................................................B-4

Volts/Amps Switch.......................................................B-4

Digital Voltmeter/Ammeter...........................................B-4

Thermal Protection Indication Light.............................B-4

Wire Feeder Receptacle..............................................B-4

High Inductance Negative Output Connection............B-4

Low Inductance Negative Connector..........................B-4

Positive Output Connector ..........................................B-4

Operating Steps ...............................................................B-5

Starting the Machine ...................................................B-5

Adjusting the Output Voltage using the Digital Meter.B-5

Using Local/Remote Switch Operation .......................B-5

Using Auxiliary Power..................................................B-5

Machine and Circuit Protection........................................B-6

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IDEALARC CV-300

B-1

OPERATION

B-1

Read and understand this entire section before
operating your Idealarc CV-300.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

____________________________________

FUMES AND GASES
can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

CAUTION

When using a CV-300 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 use with some wire feeders with the electri­cal trigger interlock in the ON position, the arc
might restart if the electrode touches the work or
ground during these several seconds.

____________________________________

GENERAL DESCRIPTION

Product Description

The IDEALARC CV-300 is a constant voltage DC
power source designed for the GMAW process with
limited FCAW capability. It features an industrial rating
of 300 amps, 32 volts, at 100% duty cycle. It complies
with the requirements for a NEMA Class I (100) power
source. It is available from the factory in one model
only, with no options other than input voltage or fre­quency.

____________________________________

WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on

containers that have held com-

bustibles.

____________________________________

ARC RAYS
can burn.

• Wear eye, ear and body
protection.

____________________________________

Only qualified personnel should operate this equip­ment. Observe all safety information throughout this
manual.

No options are available other than input voltage.
The IDEALARC CV-300 includes the following fea-

tures:

• Two inductance positions: operator can
choose the optimum output characteristics.

• Solid State Output Contactor: no noise, no
moving parts to wear.

• Digital Voltmeter/Ammeter is standard.

• 42 VAC, 10 amp auxiliary power available for
the wire feeder.

• Circuit breaker protected.

• 115 VAC, 5 amp auxiliary power available for
the wire feeder; circuit breaker protected.

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IDEALARC CV-300

B-2

OPERATION

B-2

• Magnum Twist-Mate output receptacles.

• Single MS-type (14-pin) connection for wire
feeder.

• Solid state controls, with line voltage compen­sation.

• Optional remote control capability.

• Simple controls - easy to operate.

• Electronic and thermostatic protection from
overloads.

• Submersion dipping of assembled trans­former, choke, and rectifier in special
sealing/insulating material that gives extra pro­tection against moisture and corrosive atmos­pheres.

• Microprocessor based Control PC Board has
built-in diagnostic routines.

• Compact size, requires only 19" x 26"of space.

• Modular construction for easy servicing.

MACHINE CAPABILITY

Duty Cycle

(10-Minute

Period)

100%

60%

Amps.

300
400

Volts

32
36

LIMITATIONS

The CV-300 is intended only for use with the following
FCAW electrodes:

NR-152
NR-211
NR-203 Ni 1%
NS-3M
Outershield 70 and 71

The machine has been designed primarily for the
GMAW process. The results with FCAW electrodes
other than those listed may or may not be satisfactory.

• Recessed panels protect output terminals and
controls.

• Large safety margins and protective circuits
protect rectifiers from transient voltages and
high currents.

RECOMMENDED PROCESSES AND
EQUIPMENT

The CV-300 is capable of solid wire welding within the
rated output capacity of the machine. It is capable of
welding with the following flux-cored wires:

NR-152
NR-211
NS-3M
NR-203 Ni 1%
Outershields 70 and 71

The CV-300 is recommended for use with the following
wire feeders:

LN-7
LN-742
LN-25

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IDEALARC CV-300

B-3

OPERATION

CONTROLS AND SETTINGS

All operator controls and welding connections are
located on the Case Front of the machine. See Figure
B.1 for the location of each control and connection.

B-3

7

6

8

5

4

3

9

2

1

FIGURE B.1- CV-300 Operator Controls and
Connections.

1. ON/OFF POWER SWITCH - Two position

toggle switch that controls input power to the
machine.

2. WIRE FEEDER VOLTMETER SWITCH -

This switch selects the polarity of the wire feeder
voltmeter, if so equipped. When welding electrode
positive (MIG, Outershield and some Innershield
processes) set the switch to "+".

When welding electrode negative (most Innershield
electrodes), set the switch to "-".

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13

12

11

NOTE: This switch has no effect on the welding polar­ity. In fact, if the wire feeder being used does not have
a voltmeter, the setting of this switch has no effect.

3. LOCAL/REMOTE SWITCH - When switch is

4. VOLTAGE ADJUSTMENT CONTROL

IDEALARC CV-300

10

in the LOCAL position, the welding voltage is con­trolled at the CV-300. When the switch is the
REMOTE position, the welding voltage is con­trolled remotely by a remote output control.

KNOB - Controls the CV-300 output voltage.

B-4

OPERATION

B-4

5. 115-VOLT CIRCUIT BREAKER - Protects

the 115-volt 31-32 circuit in the wire feeder recep­tacle from overloads and shorts. If this circuit
breaker opens, the CV-300 will operate normally.
However, any equipment powered by the 115-volt
circuit will not operate.

NOTE: Earlier models may have one 10amp circuit
breaker for both the 115 and 42 volt AC circuits.

6. 42-VOLT CIRCUIT BREAKER - Protects

the 42-volt 41-42 circuit in the wire feeder recepta­cle from overloads and shorts. If this circuit break­er opens, the CV-300 will operate normally.
However, any equipment powered by the 42-volt
circuit will not operate.

7. VOLTS/AMPS SWITCH - When in the “V”

position, output voltage is displayed on the digital
meter. When in the “A” position, the output current
is displayed on the digital meter.

8. DIGITAL VOLTMETER/AMMETER - The

meter displays the CV-300 output current or the
arc voltage.

11.HIGH INDUCTANCE NEGATIVE OUT­PUT TERMINAL - The high inductance con-

nection is typically used for short arc welding heav­ier welds or when using 75% Argon/25% CO
shielding gas. This connection produces a softer
arc and a flatter bead with more wash-in than the
low inductance connection. A spray type transfer
is possible with either connection.

12.LOW INDUCTANCE NEGATIVE OUT­PUT TERMINAL - The low inductance connec-

tion is typically used for short arc welding of mild
steel, particularly on thin materials or when using
CO shielding gas.

13.POSITIVE OUTPUT TERMINAL

NOTE: The positive and negative output terminals are
Magnum Twist-Mate receptacles. Insert a matching
Twist-Mate plug and twist clockwise to engage.

For GMAW processes, and some FCAW processes,
the positive output connection goes to the wire feeder.
One of the negative output connections goes directly to
the work.

NOTE: Due to voltage drops in the welding cables and
at the cable connection points, the actual arc voltage
may be lower than that displayed on the voltmeter.
Use welding cables of the proper capacity and make
sure all connections are tight to minimize this effect.

9. THERMAL PROTECTION INDICATION
LIGHT - When lit, the light indicates that the pro-

tection thermostat has activated. The digital meter
will display "E10" when this occurs. The machine
will not operate. When the light turns off, the
machine has cooled sufficiently to provide welding
output power again.

NOTE: Leaving the ON/OFF POWER SWITCH in the
"ON" position will result in the most rapid cooling.

10. WIRE FEEDER RECEPTACLE - This is a

14-pin MS style receptacle. It provides connec­tions for auxiliary power, contactor closure, remote
output control, wire feeder voltmeter sense lead,
and ground.

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IDEALARC CV-300

B-5

OPERATION

B-5

OPERATING STEPS

STARTING THE MACHINE

Turn the ON/OFF POWER SWITCH to the ON posi­tion. See Figure B.1.

ADJUSTING THE OUTPUT VOLTAGE
USING THE DIGITAL METER

The digital meter in the CV-300 incorporate a voltage
preset function. This allows the operator to set the
desired welding voltage before striking an arc. The
digital meter can also display welding current.

To make use of the voltage preset function, the
Volts/Amps switch must be in the "Volts" position. Turn
the Voltage Adjust knob until the digital meter displays
the desired welding voltage. (See below if an external
power source remote control is installed.)

NOTE: When an arc is struck, the digital meter dis­plays the actual welding voltage, as measured at the
CV-300 output terminals. The arc voltage at the elec­trode may be as much as two volts different from the
CV-300 output terminal voltage. This is due to voltage
drops present in the welding cables, cable connec­tions, and welding gun. To minimize these drops, use
cables of adequate capacity, and make sure all con­nections are clean and tight. Because of these voltage
drops, you may have to preset the CV-300 for a slight­ly higher welding voltage than your procedure calls for.

USING AUXILIARY POWER

A 42-volt AC auxiliary power source required for some
wire feeders is available through the wire feeder recep­tacle. A10-amp circuit breaker protects the 42-volt cir­cuit from overloads.

The CV-300 machine can also supply 115 volt AC aux­iliary power through the wire feeder receptacle. A 5­amp circuit breaker protects the 115 volt circuit from
overloads.

NOTE: Earlier models may have one 10amp circuit
breaker for both the 115 and 42 volt AC circuits.

NOTE: Do not use circuits 2 or 4 for control of auxil­iary loads because the 2-4 circuit is isolated from the
31-32 and 41-42 circuits.

CAUTION

Note that some types of equipment, especially
pumps and large motors, have starting currents
which are significantly higher than their running
current. These higher starting currents may cause
the circuit breaker to open. If this situation occurs,
the user should refrain from using the CV-300 aux­iliary power for that equipment.

____________________________________

To read welding current, set the Volts/Amps switch to
the "Amps" position. The welding current will be dis­played whenever an arc is struck.

USING LOCAL/REMOTE SWITCH
OPERATION

If controlling the voltage at the CV-300, the
Local/Remote switch must be in the "Local" position.
The Voltage Adjust Knob on the front panel can be
used to adjust the CV-300 output. (The remote control,
even if connected, will have no effect if the switch is in
the "Local" position).

To use a remote control, such as the K857, place the
Local/Remote switch in the "Remote" position. The
remote control now controls the output voltage. This
control may be adjusted while welding to change the
CV-300 output.

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IDEALARC CV-300

B-6

OPERATION

MACHINE AND CIRCUIT
PROTECTION

The CV-300 Control PC Board has built-in diagnostic
routines to alert the operator when trouble exists.
When a trouble condition occurs, the CV-300 meter will
display an error code, in the form “EXX”’ where “XX”
refers to a specific error. See

Section

The power source is thermostatically protected against
overload or insufficient cooling. If the machine is over­loaded, the thermostat will open, thermal protection
indicator light will turn on, and the output will be zero.
The fan will continue to run and auxiliary power will still
be available. The thermostat will remain open until
machine cools, at which time it will close and the out­put will again be available.

The CV-300 is electronically protected against over­loads and accidental short circuits. The overload pro­tection circuit automatically reduces the output current
to a safe value when an overload is detected. If the cir­cuitry senses a short circuit, it will shut off the CV-300
output. The short circuit protection circuit can be reset
by turning the CV-300 Power Switch OFF for at least
10 seconds. Remove the short before turning the
Power Switch ON again.

for an explanation of the error codes.

Troubleshooting

B-6

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IDEALARC CV-300

NOTES

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IDEALARC CV-300

ACCESSORIES

TABLE OF CONTENTS

- ACCESSORIES SECTION -

ACCESSORIES SECTION ....................................... Section C

Field Installed Accessories...............................................C-1

Remote Voltage Control (K857) ..................................C-1

One Cylinder Undercarriage (K835) ...........................C-1

Two Cylinder Undercarriage (K874)............................C-1

Wire Feeder Swivel Mount (K178-1) ...........................C-1

Universal Adapter (K867)............................................C-1

Connecting Wire Feeder to the CV-300...........................C-1

LN-7 to CV-300...........................................................C-1

LN-25 to CV-300.........................................................C-2

LN-742 to CV-300.......................................................C-2

Connecting Remote Control (K857) to CV-300................C-2

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IDEALARC CV-300

C-1

ACCESSORIES

C-1

FIELD INSTALLED ACCESSORIES

NOTE: The instructions for installing and operating
each accessory is included with the accessory.

REMOTE VOLTAGE CONTROL (K857)

The K857 Remote Voltage Control consists of a control
box with 25 feet (7.6 m) of four conductor cable.
Installation of a K857 Remote Voltage Control in the
CV-300 requires a K864 Remote Control Adapter.
Refer to the instructions provided with the K857 for
hookup to the CV-300. When properly connected and
the CV-300 LOCAL/REMOTE SWITCH in the
"Remote" position, the K857 functions the same as the
CV-300 Voltage Adjust control. This enables minimum
to maximum output voltage adjustment of the CV-300.

ONE CYLINDER UNDERCARRIAGE
(K835)

The undercarriage includes front casters, a handle, a
bracket, and a rear wheeled platform that is capable of
carrying one gas cylinder. The CV-300 lifting eye is not
functional with the K835 undercarriage installed.

CONNECTING WIRE FEEDER TO
THE CV-300

Based on the type of wire feeder being used follow the
directions for connecting it to the CV-300.

The CV-300 is intended for use with the LN-7, LN-742,
and LN-25 wire feed units. Use the Cables/Kits listed
below to make connection easily:

LN-7/LN-7GMA Requires K480 Input Cable

LN-25

LN-25 w/K444-1
Remote Voltage
Control Kit

LN-742/LN-742H Requires K591 Input Cable

Requires K484 Jumper
Plug Kit

Requires K464 Remote
Control Adapter and K484
Jumper Plug Kit

TWO CYLINDER UNDERCARRIAGE
(K874)

The two-cylinder undercarriage platform type can
accommodate either one or two gas bottles, or one gas
bottle and a Magnum water cooler. The CV-300 lifting
eye is not functional when the K874 undercarriage is
installed.

WIRE FEEDER SWIVEL MOUNT (K178-1)

This allows an LN-7 or LN-742 to be securely mounted
on the roof of a CV-300.

UNIVERSAL ADAPTER (K867)

This provides a means of connecting auxiliary equip­ment to the wire feeder receptacle on the CV-300
power source. It consists of a 14-pin MS-type
(Amphenol) plug with 8-inch (0.2 meter) long flex
leads, one for each circuit present in the wire feeder
receptacle. This adapter is not required when using a
standard Lincoln Electric wire feeder input cable, such
as a K480.

LN-7 TO CV-300

1. Turn the ON/OFF POWER SWITCH to OFF.

2. Connect the LN-7 control cable to the wire feeder
receptacle on the CV-300.

3. Connect the work and electrode cables.
a. Connect the positive output lead to the termi-

nal marked (+).

b. Connect the negative output lead to either the

low inductance terminal marked ( ) or the high
inductance terminal marked ( ).

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IDEALARC CV-300

C-2

ACCESSORIES

C-2

LN-25 TO CV-300

1. Turn the ON/OFF POWER SWITCH to OFF.

2. Plug a K484 jumper plug into the CV-300 wire
feeder receptacle.

3. Connect the work and electrode cables.
a. Connect the positive output lead to the termi-

nal marked (+).

b. Connect the negative output lead to either the

low inductance terminal marked ( ) or the high
inductance terminal marked ( ).

WARNING

The output terminals are energized at all times
when the K484 is plugged in.

3. Plug the K857 Remote Control into the 6-pin
receptacle of the K864 adapter. If possible, tape
the Remote cable to the heavy output leads, so
they can protect the smaller Remote Control cable
from damage and abuse.

____________________________________

LN-742 TO CV-300

1. Turn the ON/OFF POWER SWITCH to OFF.

2. Connect the LN-742 control cable to the wire feed­er receptacle on the CV-300.

3. Connect the work and electrode cables.
a. Connect the positive output lead to the termi-

nal marked (+).

b. Connect the negative output lead to either the

low inductance terminal marked ( ) or the high
inductance terminal marked ( ).

CONNECTING REMOTE CONTROL (K857)
TO CV-300

1. Turn the ON/OFF POWER SWITCH to OFF.

NOTE: The K864 Remote Control Adapter is required
to install the K857.

2. Plug the K864 Remote Control Adapter into the
power source's 14-pin receptacle.

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IDEALARC CV-300

NOTES

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IDEALARC CV-300

MAINTENANCE

TABLE OF CONTENTS

- MAINTENANCE SECTION -

MAINTENANCE SECTION ...................................... Section D

Safety Precautions...........................................................D-1

Routine and Periodic Maintenance..................................D-1

Component Locations.................................................D-2

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IDEALARC CV-300

D-1

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

• Have a qualified technician do the maintenance
and troubleshooting work.

• Disconnect input power at main input supply
prior to working inside machine.

____________________________________

Read the Safety Precautions in the front of this manu­al before working on this machine.

ROUTINE AND PERIODIC
MAINTENANCE

1. Disconnect input AC power supply lines to the
machine before performing periodic maintenance,
tightening, cleaning, or replacing parts. See
Figure D.1.

D-1

Perform the following daily:

1. Check that no combustible materials are in the
welding or cutting area or around the machine.

2. Remove any debris, dust, dirt, or materials that
could block the air flow to the machine for cooling.

3. Inspect the electrode cables for any slits, punc­tures in the cable jacket, or any condition that
would affect the proper operation of the machine.

Perform Periodically:

Clean the inside of the machine with low pressure air
stream. Clean the following parts. Refer to Figure D.1.

Main transformer and choke.
Electrode and work cable connections.
SCR rectifier bridge and heat sink fins.
Control board.
Fan Motor Assembly.

NOTE: The fan motor has sealed bearings which
require no maintenance.

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IDEALARC CV-300

D-2

MAINTENANCE

D-2

COVER

ASSEMBLY

MAIN TRANSFORMER

AND CHOKE ASSEMBLY

CAPACITOR AND

SCR BRIDGE RECTIFIER

ASSEMBLY

CASE BACK

ASSEMBLY

CASE FRONT

ASSEMBLY

(CONTROL BOARD

LOCATED ON BACK)

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BASE AND FAN

MOTOR ASSEMBLY

Figure D.1 - Component Locations.

IDEALARC CV-300

NOTES

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IDEALARC CV-300

INPUT

LINE

SWITCH

THEORY OF OPERATION

TABLE OF CONTENTS

- THEORY OF OPERATION SECTION -

THEORY OF OPERATION SECTION ...................... Section E

Power Supply Operation .................................................E-1

Input Line Voltage, Line Switch and

Main Transformer........................................................E-1

Output Rectification, Filtering, Control and

Feedback.....................................................................E-2

Protection Devices and Circuits...................................... E-3

SCR Operation.................................................................E-4

OUTPUT

FAN

MOTOR

115VAC

RECONNECT

PANEL

14 PIN

AMPHENOL

TRIGGER AND REMOTE

12VAC

4
2
V
A
C

12VAC

CONTROL

CONTROL BOARD

G
A
T
E
S

+

METER

F
E
E
D
B
A
C
K

SHUNT

CAPACITORS

F
E
E
D
B
A
C
K

+

OUTPUT
TERMINALS

-

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-

MAIN

TRANSFORMER

Figure E.1 - Block Logic Diagram.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

IDEALARC CV-300

OUTPUT

RECTIFIER

CHOKE

-

E-1

INPUT

LINE

SWITCH

FAN

MOTOR

115VAC

RECONNECT

PANEL

THEORY OF OPERATION

POWER SUPPLY OPERATION

OUTPUT

CONTROL

14 PIN

AMPHENOL

TRIGGER AND REMOTE

12VAC

4
2
V
A
C

12VAC

CONTROL BOARD

G
A
T
E
S

+

METER

F
E
E
D
B
A
C
K

SHUNT

CAPACITORS

E-1

F
E
E
D
B
A
C
K

+

OUTPUT
TERMINALS

-

MAIN

TRANSFORMER

Figure E.2 - Input Line Voltage, Line Switch and Main Transformer

INPUT LINE VOLTAGE, LINE SWITCH
AND MAIN TRANSFORMER

The desired three phase input power is connected to
the CV 300 through an input line switch located on the
front of the machine. Areconnect panel allows the user
to configure the machine for the desired input voltage.
This AC input voltage is applied to the primary of the
main transformer.

The main transformer changes the high voltage, low
current input power to a low voltage, high current out­put. The finishes or "neutrals" of the main secondary
coils are connected together and the three starts of the
secondary windings are connected to the rectifier
assembly. In addition the main transformer also has
several isolated auxiliary windings. The 115 VAC auxil­iary winding supplies power to operate the cooling fan
and offers up to 5 amps to operate wire feeding equip-

OUTPUT

RECTIFIER

-

CHOKE

-

ment. A separate 42 VAC winding is connected to the
14 pin amphenol to supply up to 10 amps for 42 VAC
wire feeders. The two isolated 12 VAC coils supply
power and gate firing timing information to the control
board.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

IDEALARC CV-300

E-2

INPUT

LINE

SWITCH

THEORY OF OPERATION

POWER SUPPLY OPERATION (CONTINUED)

OUTPUT

FAN

MOTOR

115VAC

RECONNECT

PANEL

14 PIN

AMPHENOL

TRIGGER AND REMOTE

12VAC

4
2
V
A
C

12VAC

CONTROL

CONTROL BOARD

G
A
T
E
S

+

METER

F
E
E
D
B
A
C
K

SHUNT

CAPACITORS

E-2

F
E
E
D
B
A
C
K

+

OUTPUT
TERMINALS

-

MAIN

TRANSFORMER

Figure E.3 - Output Rectification, Filtering, Control and Feedback

OUTPUT RECTIFICATION, FILTERING,
CONTROL AND FEEDBACK

The main transformer secondary windings are con­nected to an SCR/Diode hybrid rectifier bridge. This
three phase AC output from the main transformer sec­ondary is rectified and controlled through the rectifier
bridge. Output current and voltage are sensed at the
shunt and the output terminals and fed back to the con­trol board. This feedback information is processed in
the control board. The control board compares the
commands of the output control potentiometer (or
remote control) with the feedback information and
sends the appropriate gate firing signals to the rectifier
bridge. The control board also supplies power and sig­nals to the meter board.

OUTPUT

RECTIFIER

-

CHOKE

-

The capacitors and the output choke provide the filter­ing for the controlled DC output of the CV 300
machine. The choke is tapped for supplying either a
soft (high inductance) or a more harsh (low induc­tance) welding arc.

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NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

IDEALARC CV-300

E-3

THEORY OF OPERATION

PROTECTION DEVICES AND CIRCUITS

Athermostat protects the CV-300 from excessive oper­ating temperatures. Excessive operating temperatures
may be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostat will open and deactivate the machine’s out­put. The thermal protection light will light (on earlier
codes the pilot light will flash) and the fan will continue
to run. The thermostat will remain open until the
machine cools, at which time the machine will resume
normal operation. If the fan does not turn or the air
intake louvers are obstructed, then the input power
must be removed and the fan problem or air obstruc­tion be corrected.

The CV-300 is also protected against high current
overloads. If this electronic protection circuit senses a
current overload the machine’s output will be disabled.
The electronic protection circuit can be reset either by
turning the line switch off for ten seconds or by open­ing the trigger circuit (leads #2 and #4) for five sec­onds.

E-3

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IDEALARC CV-300

E-4

INPUT

CATHODE

THEORY OF OPERATION

SCR OPERATION

E-4

OUTPUT

ANODE

GATE

Figure E.4 - SCR Operation

A silicon controlled rectifier (SCR) is a three terminal
device used to control rather large currents to a load.
An SCR acts very much like a switch. When a gate sig­nal is applied to the SCR it is turned ON and there is
current flow from anode to cathode. In the ON state the
SCR acts like a closed switch. When the SCR is turned
OFF there is no current flow from anode to cathode
thus the device acts like an open switch. As the name
suggests, the SCR is a rectifier, so it passes current
only during positive half cycles of the AC supply. The
positive half cycle is the portion of the sine wave in
which the anode of the SCR is more positive than the
cathode.

When an AC supply voltage is applied to the SCR, the
device spends a certain portion of the AC cycle time in
the off state and the remainder of the time in the on
state. The amount of time spent in the ON state is con­trolled by the gate.

NOTE: AS THE GATE
PULSE IS APPLIED
LATER IN THE CYCLE
THE SCR OUTPUT
IS DECREASED.

An SCR is fired by a short burst of current into the gate.
This gate pulse must be more positive than the cath­ode voltage. Since there is a standard PN junction
between gate and cathode, the voltage between these
terminals must be slightly greater than 0.6V. Once the
SCR has fired it is not necessary to continue the flow
of gate current. As long as current continues to flow
from anode to cathode the SCR will remain on. When
the anode to cathode current drops below a minimum
value, called holding current, the SCR will shut off. This
normally occurs as the AC supply voltage passes
through zero into the negative portion of the sine wave.
If the SCR is turned on early in the positive half cycle,
the conduction time is longer resulting in greater SCR
output. If the gate firing occurs later in the cycle the
conduction time is less resulting in lower SCR output.

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IDEALARC CV-300

NOTES

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IDEALARC CV-300

TROUBLESHOOTING & REPAIR

TABLE OF CONTENTS

- TROUBLESHOOTING & REPAIR SECTION -

TROUBLESHOOTING & REPAIR SECTION ........... Section F

How to use Troubleshooting Guide.......................................F-1

PC Board Troubleshooting Procedures................................F-2

Troubleshooting Guide ..........................................................F-3

Diagnostic Routines and Error Codes ................................F-10

Test Procedures

Main Transformer Test....................................................F-11

Static Output Rectifier Bridge Test .................................F-14

Active SCR Rectifier Assembly Test...............................F-18

Oscilloscope Waveforms.....................................................F-22

Normal Open Circuit Weld Voltage Waveform

No Load - Output Control at Maximum .....................F-22

Typical DC Weld Output - Machine Loaded...................F-23

Abnormal Output Weld Waveform - Machine

Loaded One Output SCR Not Functioning ................F-24

Abnormal Output Weld Voltage Waveform -

Machine Loaded Capacitor Bank Not Functioning ....F-25

Abnormal Open Circuit Weld Voltage Waveform -

No Load Capacitor Bank Not Functioning .................F-26

Typical SCR Gate Voltage Waveform ............................F-27

Replacement Procedures

Control PC Board Removal and Replacement...............F-28

Capacitor Bank Removal and Replacement..................F-30

Output Rectifier Bridge Removal and Replacement ......F-33

Mounting of Stud Type Diodes to Aluminum

Heat Sinks......................................................................F-35

SCR Removal and Replacement ...................................F-37

Fan Motor and Fan Removal and Replacement............F-43

Center Assembly Removal and Replacement................F-45

Retest After Repair.........................................................F-47

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IDEALARC CV-300

F-1

TROUBLESHOOTING & REPAIR

F-1

HOW TO USE TROUBLESHOOTING GUIDE

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
(SYMPTOMS)”. This column describes pos­sible symptoms that the machine may exhib­it. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function prob­lems, and welding problems.

Step 2. PERFORM EXTERNAL TESTS.

The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF
ACTION

The last column labeled “Recommended
Course of Action” lists the most likely com­ponents that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject com­ponent is either good or bad. If there are a
number of possible components, check the
components in the order listed to eliminate
one possibility at a time until you locate the
cause of your problem.

All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical trou­bleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.

_____________________________________________________________

IDEALARC CV-300

F-2

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

F-2

WARNING

ELECTRIC SHOCK can kill.
Have an electrician install
and service this equip­ment. Turn the input power
OFF at the fuse box before
working on equipment. Do
not touch electrically hot
parts.

_______________________________

CAUTION: Sometimes machine failures
appear to be due to PC board failures. These
problems can sometimes be traced to poor
electrical connections. To avoid problems
when troubleshooting and replacing PC
boards, please use the following procedure:

1. Determine to the best of your technical abil­ity that the PC board is the most likely com­ponent causing the failure symptom.

2. Check for loose connections at the PC
board to assure that the PC board is prop­erly connected.

3. If the problem persists, replace the suspect
PC board using standard practices to avoid
static electrical damage and electrical
shock. Read the warning inside the static
resistant bag and perform the following pro-

cedures:

static-dissipative.

- Remove the P.C. Board from the static­shielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or
near paper, plastic or cloth which could have a
static charge. If the P.C. Board can’t be
installed immediately, put it back in the static­shielding bag.

- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation is
complete.

- If you return a P.C. Board to The Lincoln
Electric Company for credit, it must be in the
static-shielding bag. This will prevent further
damage and allow proper failure analysis.

4. Test the machine to determine if the failure
symptom has been corrected by the
replacement PC board.

NOTE: It is desirable to have a spare (known
good) PC board available for PC board trou­bleshooting.

NOTE: Allow the machine to heat up so that
all electrical components can reach their oper­ating temperature.

5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.

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P.C. Board can be dam­aged by static electricity.

- Remove your body’s stat-

ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations

Reusable
Container
Do Not Destroy

grounded, part of the equipment frame. Keep
touching the frame to prevent static build-up.
Be sure not to touch any electrically live parts at
the same time.

- Tools which come in contact with the P.C.
Board must be either conductive, anti-static or

ic charge before opening
the static-shielding bag.
Wear an anti-static wrist
strap. For safety, use a 1
Meg ohm resistive cord
connected to a grounded
part of the equipment
frame.

- If you don’t have a wrist
strap, touch an unpainted,

IDEALARC CV-300

a. If the original problem does not reap-

pear by substituting the original board,
then the PC board was not the prob­lem. Continue to look for bad connec­tions in the control wiring harness,
junction blocks, and terminal strips.

b. If the original problem is recreated by

the substitution of the original board,
then the PC board was the problem.
Reinstall the replacement PC board
and test the machine.

6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.

NOTE: Following this procedure and writing
on the warranty report, “INSTALLED AND
SWITCHED PC BOARDS TO VERIFY PROB­LEM,” will help avoid denial of legitimate PC
board warranty claims.

F-3

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-3

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is Evident

Machine is dead - No output, no fan, no display.

The machine has no output. The fan runs and the display lights.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Contact your local Lincoln
Electric Authorized Field
Service Facility.

1. Check for blown or missing
fuses in the input line.

2. Check the three phase input line
voltage at the machine. Input
voltage must match the rating
plate and the reconnect panel.

1. Make sure the thermal light is
NOT lit (earlier codes the pilot
light is NOT blinking). If either
condition exists, then the
machine may be overheated.

2. If an error message is dis­played, see

Explanation of

Error Messages.

3. Make sure the three phase input
voltage matches the reconnect
panel configuration and that all
three phases are applied to the
machine.

4. Place a jumper wire from pin “C”
to pin “D” at the 14 pin amphe­nol connection. If output is
restored, then check the
wirefeeder and associated con­trol cable.

RECOMMENDED

COURSE OF ACTION

1. Contact The Lincoln Electric
Service Dept. [phone] or
1-800-833-9353 (WELD)

1. Check input line switch may be
faulty. Check or replace.

2. Remove the input power and
check for loose or broken leads
at the reconnect panel and at
the main transformer primary
coils.

3. Perform

Main Transformer

Test.

1. Check the trigger circuit (#2 and
#4) for continuity from the 14 pin
amphenol to the control board.
See wiring diagram.

2. If the machine has output in
machine control but not in
remote control, check the
remote switch (S4). Check the
wiring to the control board and
to the 14 pin amphenol.

3. Perform the

Main Transformer

Test.

4. Perform the

Output Rectifier

Bridge Test.

5. Check the latching resistor (R1)
and the associated leads. See
wiring diagram.

6. Check for leaking or faulty
capacitors.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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5. Place the remote switch in
machine control. If output is
restored, then the remote con­trol unit may be faulty . Check or
replace.

CAUTION

IDEALARC CV-300

7. Check for loose or faulty con­nections at the output terminals
and the heavy current carrying
leads.

8. The control board may be faulty .
Replace.

F-4

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-4

PROBLEMS

(SYMPTOMS)

The machine has low output and no
control. The fan runs and the dis­play is lit.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Place the remote switch in
machine control. If normal out­put is restored then the remote
control unit may be faulty.
Check or replace.

2. If an error message is displayed
see

Explanation of Error

Messages

3. Make sure the three phase input
voltage matches the reconnect
panel configuration and that all
three phases are applied to the
machine.

.

RECOMMENDED

COURSE OF ACTION

1. If the machine has normal out­put in machine control, but not in
remote control, check the
remote switch (S4). Check the
wiring to the control board and
to the 14 pin amphenol.

2. If the machine has low output in
machine control check the out­put control (R2) and associated
leads.

3. Check the feedback leads from
the shunt and the output termi­nals to the control board. See
wiring diagram.

4. Perform the

Main Transformer

Test.

5. Perform the

Output Rectifier

Bridge Test.

6. Check the latching resistor (R1)
and the associated leads. See
wiring diagram.

7. Check for loose or faulty con­nections at the output terminals
and the heavy current carrying
leads.

8. The control board may be faulty .
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

IDEALARC CV-300

F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-5

PROBLEMS

(SYMPTOMS)

Machine has high output and no control.

Machine does not have maximum output.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

OUTPUT PROBLEMS

1. Place the remote switch in
machine control. If normal out­put is restored then the remote
control unit may be faulty.
Check or replace.

2. Turn off the machine. Wait one
minute. If the problem is
resolved when restarted, switch
positions of any two of the input
lines.

1. Place the remote switch in
machine control. If normal out­put is restored then the remote
control unit may be faulty.
Check or replace.

2. The input voltage may be "dip­ping" when the machine is
under load. Check.

3. Make sure all three input phas­es are applied to the machine.

RECOMMENDED

COURSE OF ACTION

1. Perform the

Main Transformer

Test.

2. Perform the

Output Rectifier

Bridge Test.

3. Check the output control (R2)
and associated leads.

4. The control board may be faulty .
Replace.

1. Check the output control (R2)
and associated leads.

2. Perform the

Main Transformer

Test.

3. Perform the

Output Rectifier

Bridge Test.

4. The control board may be faulty .
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

IDEALARC CV-300

F-6

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-6

PROBLEMS

(SYMPTOMS)

The meter does not light. The machine operates properly.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

FUNCTION PROBLEMS

1. The meter board may be faulty.
Contact your local Lincoln
Authorized Field Service Facility .

RECOMMENDED

COURSE OF ACTION

1. Check for 5 VDC from lead
#208(+) to lead #210(-) at plug
J7 located on the meter board. If
the correct voltage is present the
meter board may be faulty.
Replace.

2. If the correct voltage is NOT pre­sent at leads #208 and #210,
then check the continuity (zero
ohms) of the leads between
plugs J4 and J7. See wiring dia­gram.

3. If the leads and connections are
good and the voltage is NOT
correct, then the control board
may be faulty. Replace.

The meter display reading is incor­rect.

1. The meter voltage reading may
be different then the actual arc
voltage because the CV-300
meter is measuring voltage at
the machine's output terminals.
There may be a voltage drop in
the welding cables.

1. Check the continuity (zero
ohms) of the leads between plug
J7 on the meter board and plug
J4 on the control board.

2. Check for loose or faulty con­nections on the feedback leads
#219, #218, #213B, #214B and
#224B. See wiring diagram.

3. Check the connections at the
shunt. See wiring diagram.

4. The meter board may be faulty.
Replace.

5. The control board may be faulty.
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

IDEALARC CV-300

F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-7

PROBLEMS

(SYMPTOMS)

The machine will NOT shut off.

The output voltage cannot be pre­set.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

FUNCTION PROBLEMS

1. Make sure the three phase input
lines are connected to the
machine correctly.

2. Contact your local Lincoln
Authorized Field Service
Facility.

1. Place the remote switch in
machine control. If normal oper­ation is restored then the remote
control unit may be faulty.
Check or replace.

2. If an error message is displayed
see

Explanation of Error

Messages

.

RECOMMENDED

COURSE OF ACTION

1. The input line switch may be
faulty. Replace.

1. Check the output control (R2)
and associated circuitry.

2. The meter board may be faulty.
Replace.

3. The control board may be faulty .
Replace.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

IDEALARC CV-300

F-8

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-8

PROBLEMS

(SYMPTOMS)

The output voltage cannot be pre­set.

The weld output terminals are always electrically “hot”.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

FUNCTION PROBLEMS

1. Place the remote switch in
machine control. If normal oper­ation is restored then the remote
control unit may be faulty.
Check or replace.

2. If an error message is displayed
see

Explanation of Error

Messages

1. Remove any control cable that
may be connected to the 14 pin
amphenol. If the problem is
resolved the fault is in the con­trol cable or the wire feeder.

2. If some open circuit voltage is
present (over 3 VDC.) after per­forming Step #1 then the prob­lem is within the CV300.
Contact your local Lincoln
Authorized Field Service
Facility.

.

RECOMMENDED

COURSE OF ACTION

1. Check the output control (R2)
and associated circuitry.

2. The meter board may be faulty.
Replace.

3. The control Board may be faulty .
Replace.

1. Check for an internal short
between leads #2 and #4. See
wiring diagram.

2. Perform the

Bridge Test

3. The snubber board may be
faulty. Replace.

Output Rectifier

.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact yourLocal
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

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CAUTION

IDEALARC CV-300

F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

F-9

PROBLEMS

(SYMPTOMS)

The welding arc is variable and slug­gish.

The arc striking is poor.

POSSIBLE AREAS OF
MISADJUSTMENTS(S)

WELDING PROBLEMS

1. Check the welding cable con­nections for loose or faulty con­nections.

2. Make sure the wire feed speed,
voltage, and shielding gas are
correct for the process being
used.

1. Check the welding cable con­nections for loose or faulty con­nections.

2. Make sure the wire feed speed,
voltage, and shielding gas are
correct for the process being
used.

RECOMMENDED

COURSE OF ACTION

1. Perform the

Bridge Test.

2. The control board may be faulty .
Replace.

1. The control board may be faulty .
Replace.

Output Rectifier

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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CAUTION

IDEALARC CV-300

F-10

TROUBLESHOOTING & REPAIR

DIAGNOSTIC ROUTINES AND ERROR CODES

The CV-300 Meter PC Board displays error codes
when certain trouble conditions exist. The error codes,
trouble conditions and possible remedies are listed
below.

F-10

ERROR

CODE

E00

E10

E20

E30

TROUBLE

1. Output short circuited.

2. May be encountered while starting or
welding with 1/16” aluminum wire.

Thermostat circuit has opened.

Memory error.

1. Voltage Adjust potentiometer not
connected.

REMEDY

1. Turn power off. Remove short cir­cuit.

2. (a) Turn power off to clear error.

Use recommended wfs, volt­age settings and angle of
approach of wire to work.

(b) If problem persists, call Lincoln

Authorized Field Service
Facility.

Allow machine to cool. Be sure to pro­vide adequate ventilation to machine.

Perform
verify PC Board input voltages.
Control Board may be faulty.

1. Check wiring between Voltage

Main Transformer Test

Adjust and the Control PC Board.

to

If, after attempting the remedies listed above, the error
condition still exists, the problem may be with the
wiring in the following areas: the shunt (leads 218 and

219), or voltage feedback (leads 213B, 214B, and
224B).

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con­tact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216­383-2531 or 1-800-833-9353

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E40

E50

E60

2. Remote Control not functioning cor­rectly.

Input line voltage too low.

Input line voltage too high.

Overload condition.

CAUTION

IDEALARC CV-300

2. See

(Function Problems)

Turn Power off. Insure machine input
voltage is within specifications. Turn
power back on.

Turn Power off. Insure machine input
voltage is within specifications. Turn
power back on.

Reduce load on machine.

Troubleshooting Guide

.

F-11

TROUBLESHOOTING & REPAIR

F-11

MAIN TRANSFORMER TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

TEST DESCRIPTION

This test will determine if the correct voltages are being:
a. Applied to the primary windings of the Main Transformer.
b. Induced on the secondary and auxiliary windings of the main transformer.

MATERIALS NEEDED

Volt-Ohm Meter (Multimeter).
IDEALARC CV-300 wiring diagrams (See Electrical Diagrams Sections of this manual).

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IDEALARC CV-300

F-12

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST (CONTINUED)

F-12

TEST PROCEDURE

WARNING

The ON/OFF POWER SWITCH will be
"hot" during these tests.

__________________________

NOTE: Secondary voltages will vary pro­portionably with the primary AC input
voltage.

1. Disconnect the main input power to
the machine.

2. Remove the case roof and case side
panels.

3. Test for correct three-phase voltage
being applied to the main trans­former.

a. If the correct three-phase volt-

age is being applied to the main
transformer, continue test.

9. Locate lead # 33 connected to cir­cuit breaker CB2 and pin "J" (lead
#31) on the 14 pin amphenol con­nector located on the Case Front.
See Figure F.1.

FRONT PANEL

14 PIN AMPHENOL

CONNECTOR (PIN J)

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b. If the incorrect three-phase volt-

age is not being applied to the
main transformer, correct before
proceeding with test.

4. Locate plug J3 on the Control PC
Board.

5. Locate the following leads on plug
J3: #200, #201, #202, and #203.

6. Re-connect main input power to the
machine.

7. Turn the ON/OFF POWER SWITCH
to ON.

8. Test for 12 VAC

FROM LEAD

#200
#202

a. Insert the meter probes careful-

ly into the back of each Molex
Plug pin cavity until electrical
contact is made to perform the
test.

TO LEAD

#201
#203

IDEALARC CV-300

CIRCUIT BREAKER

CB2 (LEAD #33)

FIGURE F.1 - Main Transformer Test
Points.

10. Test for 115 VAC between lead #33
at circuit breaker and pin "J" (lead
#31) on the amphenol connector.

a. If voltage is missing, check for

loose or broken wires between
test points and main trans­former. See CV-300 wiring dia­gram.

b. If voltage is present, continue

test.

F-13

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST (CONTINUED)

F-13

11. Locate lead #42A (lead #33 on
machine codes below 9900) con­nected to circuit breaker CB1 and
pin "I" on the 14 pin amphenol con­nector on the Case Front. See
Figure F.2.

FRONT PANEL

14 PIN AMPHENOL

CONNECTOR (PIN I)

b. If voltage is present, continue

test.

13. Locate the following heavy leads
connected to output rectifier bridge:
#221, #222, and #223. See Figure
F.3.

LEAD #221

LEAD #222

CIRCUIT BREAKER

CB1 (LEAD #42A)

FIGURE F.2 - Main Transformer Test
Points.

12. Test for 42 VAC between lead #42A
at the circuit breaker (lead #33 on
machine codes below 9900) and pin
"I" on the on the amphenol connec­tor.

a. If voltage is missing, check for

loose or broken wires between
the test points and the main
transformer. See wiring dia­gram.

LEAD #223

MAIN TRANSFORMER

FIGURE F.3 - Location of leads #221,
#222, and #223.

14. Test for 36 VAC.

FROM LEAD

#221
#223
#222

TO LEAD

#222
#221
#223

15. If the correct three-phase input volt­age is being applied to the main
transformer and some or all of the
secondary voltages are incorrect or
missing, the transformer may be
faulty. Replace.

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IDEALARC CV-300

F-14

TROUBLESHOOTING & REPAIR

F-14

STATIC OUTPUT RECTIFIER BRIDGE TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

TEST DESCRIPTION

This test is used to quickly determine if an SCR or diode is shorted or "leaky." See the
Machine Waveform Section in this manual for normal and abnormal output waveforms.

MATERIALS NEEDED

Analog Volt-Ohm Meter (Multimeter).
CV-300 Wiring Diagrams (See Electrical Diagrams Section of this Manual).
1/2" Wrench.
7/16" Wrench.

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IDEALARC CV-300

F-15

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST (CONTINUED)

TEST PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Locate and remove the following
plugs:

Note: Location of plugs will vary depend­ing on code.

F-15

PLUG

J5
J1
J3

See Figure F.4.

CONTROL

BOARD

LOCATION

Snubber board

Control board

Control Board

SNUBBER

BOARD

FIGURE F.5 - Procedure to disconnect
the strap from the positive heat sink
to the capacitor bank.

5. Disconnect the D5 diode pigtail from
the negative capacitor buss using a
1/2" wrench. See Figure F.6.

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FIGURE F.4 - Plug locations.
Location of plugs will vary depending
on code.

3. Locate resistor R1 and remove lead
#224. See wiring diagram

4. Disconnect the strap from the posi­tive heat sink to the capacitor bank
using a 1/2" wrench. See Figure
F.5.

FIGURE F.6 - Procedure to disconnect
the D5 diode pigtail from the negative
capacitor buss.

IDEALARC CV-300

F-16

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST (CONTINUED)

F-16

6. Disconnect the D4 diode pigtail from
the positive strap. See Figure F.7.

NOTE: DO NOT DISASSEMBLE THE
HEAT SINKS.

8. Test SCR1 for proper resistance.
Resistance should be high or infi­nite.

a. Measure the resistance from the

anode to cathode of SCR1
using an analog volt-ohm meter
(Multi meter) set at R X 1000
scale. See Figure F.9.

FIGURE F.7 - Procedure to disconnect
the D4 diode pigtail from the positive
strap.

7. Remove the red insulating paint
from the heat sink test points. See
Figure F.8.

NODE

CATHODE

FIGURE F.9 - SCR test points.

b. Reverse the meter leads and

measure the resistance from the
cathode to anode of SCR1. See
Figure F.9.

c. If a low resistance is measured

for either test a or b, SCR1 is
faulty. Replace the SCR
assembly.

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FIGURE F.8 - Heat sink test points.

IDEALARC CV-300

9. Test the resistance of SCR2 and
SCR3 using the same procedure
described in Step 8.

F-17

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST (CONTINUED)

10. Test diode D1 for proper operation.
a. Measure the resistance of diode

D1 from the anode (+ probe) to
the cathode (- probe) using an
analog volt-ohm meter
(Multimeter) set at R X 1000
scale. Resistance should be
low. See Figure F.10.

F-17

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FIGURE F.10 - Diode D1 test points.

b. Reverse the meter leads and

measure the resistance from the
cathode (+ probe) to anode (­probe) of D1. Resistance
should be High. See Figure
F.10.

c. If the resistance is low for both

tests a and b, the diode is short­ed. Replace.

d. If the resistance is high for both

test a and b, the diode is open.
Replace.

11. Test Diodes D2, D3, and D4 for
proper operation using the same
procedure described in Step 10.

12. Reconnect all leads and Molex
plugs disconnected for this test.

13. If this test did not identify the prob­lem or to further test the SCR, go to
the

Active SCR Test

IDEALARC CV-300

.

F-18

TROUBLESHOOTING & REPAIR

F-18

ACTIVE SCR RECTIFIER ASSEMBLY TEST

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

TEST DESCRIPTION

The Active SCR Test will determine if the device is able to be gated ON and conduct current
from anode to cathode.

MATERIALS NEEDED

An SCR Tester as specified in this procedure.
IDEALARC CV-300 wiring diagrams (See Electrical Diagrams Section of this Manual).
Output Rectifier Bridge Heat Sink Assembly Drawings.

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IDEALARC CV-300

F-19

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

TEST PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Locate and remove the following
plugs:

F-19

PLUG #

J5
J1
J3

See Figure F.11.

CONTROL

BOARD

LOCATION

Snubber board

Control board

Control Board

SNUBBER

BOARD

FIGURE F.12 - Procedure to discon­nect the strap from the positive heat
sink to the capacitor bank.

5. Disconnect the D5 diode pigtail from
the negative capacitor buss using a
1/2" wrench. See Figure F.13.

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FIGURE F.11 - Molex plug locations.

3. Locate resistor R1 and remove lead
#224. See wiring diagram.

4. Disconnect the strap from the posi­tive heat sink to the capacitor bank
using a 1/2" wrench. See Figure
F.12.

FIGURE F.13 - Procedure to discon­nect the D5 diode pigtail from the
negative capacitor buss.

IDEALARC CV-300

F-20

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

F-20

6. Disconnect the D4 diode pigtail from
the positive strap. See Figure F.14.

FIGURE F.14 - Procedure to discon­nect the D4 diode pigtail from the
positive strap.

7. Remove the red insulating paint
from the heat sink test points. See
Figure F.15.

NOTE: DO NOT DISASSEMBLE THE
SCR RECTIFIER HEAT SINK ASSEM­BLY.

8. Construct the circuit shown in Figure
F.16. One 6-volt lantern battery can
be used. R1 and R2 resistor values
are 010%. Set voltmeter scale low,
at approximately 0-5 volts or 5-10
volts.

a. Test the voltage level of the bat-

tery. Short leads (A) and (B).
Close switch SW-1. Battery
voltage should be 4.5 volts or
higher. If lower, replace the bat­tery.

9. Connect the Tester to the SCR 1 as
shown in Figure F.16.

a. Connect Tester lead (A) to the

anode.

b. Connect Tester lead (C) to the

cathode.

c. Connect Tester lead (G) to the

gate.

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FIGURE F.15 - Heat sink test points.

IDEALARC CV-300

ANODE

CATHODE

FIGURE F.16 - SCR Tester Circuit and
SCR connections.

F-21

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST (CONTINUED)

F-21

10. Close switch SW-1.
NOTE: Switch SW-2 should be open.

11. Read meter for zero voltage.
a. If the voltage reading is higher

than zero, the SCR is shorted.

12. Close or keep closed switch SW-1.

13. Close switch SW-2 for 2 seconds
and release and read meter.

a. If the voltage is 3 - 6 volts while

the switch is closed and after
the switch is open, the SCR is
functioning.

b. If the voltages is 3-6 volts only

when the switch is closed or
there is no voltage when the
switch is closed, the SCR is
defective.

18. Perform the Active Test Procedure
outlined in Steps 9-17 for SCR 2.

19. Replace all SCR assemblies that do
not pass the above tests.

20. Replace all disconnected leads and
Molex Plugs.

NOTE: Be sure battery is functioning
properly. A low battery can affect the
results of the test. Repeat Battery Test
Procedure in Step 6 if needed.

14. Open switch SW-1.

15. Reconnect the Tester leads. See
Figure F.16.

a. Connect Tester lead (A) to the

cathode.

b. Connect Tester lead (C) to the

anode.

c. Disconnect Test lead (G) from

the gate.

16. Close switch SW-1.

17. Read meter for zero voltage.
a. If the voltage is zero, the SCR is

functioning.

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b. If the voltage is higher than

zero, the SCR is shorted.

IDEALARC CV-300

F-22

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

NO LOAD - OUTPUT CONTROL AT MAXIMUM

CH1

0 Volts

F-22

20V

This is a typical output voltage generated
from a properly operating machine. Note
that each vertical division represents 20
volts and that each horizontal division rep­resents 5 milliseconds in time.

Note: Scope probes connected at machine
high inductance output terminals.

5ms

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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IDEALARC CV-300

F-23

TROUBLESHOOTING & REPAIR

TYPICAL DC WELD OUTPUT - MACHINE LOADED

CH1

0 Volts

F-23

20V

MACHINE LOADED TO 300 AMPS AT 32 VDC

This is a typical CV output voltage generat­ed from a properly operating machine. Note
that each vertical division represents 20
volts and that each horizontal division rep­resents 5 milliseconds in time.
The machine was loaded with a resistance
grid bank.

Note: Scope probes connected at machine
high inductance output terminals.

5ms

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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IDEALARC CV-300

F-24

TROUBLESHOOTING & REPAIR

ABNORMAL OUTPUT WELD VOLTAGE WAVEFORM -

MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING

CH1

0 Volts

F-24

20V

MACHINE LOADED TO 300 AMPS AT 32 VDC

This is not a typical CV output voltage wave­form. Note the “ripple” in the waveform.
One output SCR was disconnected to simu­late an open or non-functioning output SCR.
Note that each vertical division represents
20 volts and each horizontal division repre­sents 5 milliseconds in time.

Note: Scope probes connected at machine
high inductance output terminals.

5ms

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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IDEALARC CV-300

F-25

TROUBLESHOOTING & REPAIR

ABNORMAL OUTPUT WELD VOLTAGE WAVEFORM - MACHINE LOADED

CAPACITOR BANK NOT FUNCTIONING

CH1

0 Volts

F-25

20V

MACHINE LOADED TO 300 AMPS AT 32 VDC

This is NOT the typical output voltage wave­form. Note the increased “ripple” in the out­put waveform. The output capacitors were
disconnected to simulate a faulty capacitor
bank. Note that each vertical division repre­sents 20 volts and each horizontal division
represents 5 milliseconds in time.

Note: Scope probes connected at machine
high inductance output terminals.

5ms

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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IDEALARC CV-300

F-26

TROUBLESHOOTING & REPAIR

ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

NO LOAD - CAPACITOR BANK NOT FUNCTIONING

CH1

0 Volts

F-26

20V

This is not the typical output voltage wave­form. The output capacitors were discon­nected to simulate a faulty capacitor bank.
Note the absence of “filtering” in the wave­form. Note that each vertical division repre­sents 20 volts and each horizontal division
represents 5 milliseconds in time.

Note: Scope probes connected at machine
high inductance output terminals.

5ms

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . .20 V/Div.

Horizontal Sweep . . . . . . . . . .5 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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IDEALARC CV-300

F-27

TROUBLESHOOTING & REPAIR

TYPICAL SCR GATE VOLTAGE WAVEFORM

CH1

0 Volts

F-27

1V

This is the typical SCR gate pulse voltage
waveform. The machine was in an open cir­cuit condition (no load) and operating prop­erly. Note that each vertical division repre­sents 1 volt and that each horizontal division
represents 2 milliseconds in time.

Note: Scope probes connected at SCR gate
and cathode: (+) probe to gate, (-) probe to
cathode.

2ms

SCOPE SETTINGS

Volts/Div . . . . . . . . . . . . . . . . . .1 V/Div.

Horizontal Sweep . . . . . . . . . .2 ms/Div.

Coupling . . . . . . . . . . . . . . . . . . . . .DC.

Trigger . . . . . . . . . . . . . . . . . . .Internal.

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IDEALARC CV-300

F-28

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

F-28

_____________________________________________________________

CAUTION

Printed Circuit Boards can be damaged by static electricity. Follow static handling guidelines
detailed in “PC Board Troubleshooting Procedures” at the beginning of this chapter.

_____________________________________________________________

REMOVAL AND REPLACEMENT PROCEDURE

PROCEDURE DESCRIPTION

This procedure will aid the technician in removing and replacing the Control PC Board for
maintenance or replacement.

MATERIALS NEEDED

5/16" Nutdriver.
3/8" Nutdriver.
Phillips head screwdriver.
Wiring Diagram.

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IDEALARC CV-300

F-29

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT

PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Remove the Case Roof.

3. Disconnect the Molex plugs from the
control board.

4. Remove the four screws located on
the outboard side of the Case Front
panel that mount the control board
to the front panel.

5. Remove the control board from the
mounting studs carefully.

6. Replace all insulating material,
mounting screws, and Molex plugs
when installing the control board.

F-29

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IDEALARC CV-300

F-30

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-30

WARNING

THE LIQUID ELECTROLYTE IN THE CAPACITORS IS TOXIC. DO NOT TOUCH THE
CAPACITORS WITH ANY PART OF THE BODY. USE INSULATED GLOVES WHEN HAN­DLING CAPACITORS.

_____________________________________________________________

MATERIALS NEEDED

5/16" Nutdriver.
3/8" Nutdriver.
1/2" Open end wrench.
7/16" Open end wrench.
Wiring diagram.

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IDEALARC CV-300

F-31

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT (CONTINUED)

PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Test that the capacitors are dis­charged using a voltmeter.

a. Polarity must be observed.

3. Disconnect the following compo­nents from the capacitor bank
assembly: See Figure F. 17.

F-31

PART TO REMOVE

Diode D1 pigtail and lead #224A

Diode D2 pigtail

Diode D3 pigtail, output choke

lead, and leads #224 and #224B

Diode D5 pigtail
Diode D4 pigtail

Positive capacitor jumper strap

Positive capacitor output lead

4. Remove the two screws holding the
capacitor mounting strap to the lift
bail assembly using a 5/16"
Nutdriver.

a. Note placement of insulation.

LOCATION

Negative capacitor bank buss
Negative capacitor bank buss
Negative capacitor bank buss

Negative capacitor bank buss

Positive capacitor jumper strap

Positive capacitor buss
Positive capacitor buss

TYPE WRENCH

1/2" open end wrench
1/2" open end wrench
1/2" open end wrench

1/2" open end wrench

7/16" open end wrench

1/2" open end wrench
1/2" open end wrench

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5. Carefully remove the capacitor bank
assembly.

IDEALARC CV-300

F-32

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT (CONTINUED)

LEAD #224

LEAD #224B

OUTPUT CHOKE LEAD

F-32

D3 PIGTAIL

D4 PIGTAIL

POSITIVE STRAP

FIGURE F.17 - Capacitor Bank Removal.

D5 PIGTAIL

D2 PIGTAIL

MOUNTING STRAP

POSITIVE

OUTPUT

LEAD

POSITIVE BUSS

LEAD #224A

D1 PIGTAIL

NEGATIVE BUSS

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IDEALARC CV-300

F-33

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL & REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-33

MATERIALS NEEDED

5/16" Nutdriver.
3/8" Nutdriver.
1/2" Open end wrench.
7/16" Open end wrench.
Wiring diagram.

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IDEALARC CV-300

F-34

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL & REPLACEMENT (CONTINUED)

F-34

PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Remove the Case Roof and Case
Sides.

3. Test the capacitors are discharged
using a voltmeter.

a. Polarity must be observed.

4. Remove the Capacitor Bank
Assembly

a. Use the steps given in the

Capacitor Bank Assembly
Removal Procedure in this sec­tion of the manual.

5. Disconnect the three transformer
secondary leads connected to the
three SCR heat sinks using a 1/2"
open wrench. See Figure F. 18.

10. Remove the rectifier bridge assem­bly carefully from the machine.

a. Clear or cut any cable ties or

leads that may hamper the
removal of the assembly.

TRANSFORMER

SECONDARY

LEADS

a. Disconnect leads #221, #222,

and #223.

b. Note placement of leads for re-

assembly.

6. Remove plug J1 from the control
board.

7. Cut any cable ties that would restrict
the removal of the assembly.

8. Disconnect the three #204 leads
connected to the bottom of the pos­itive SCR heat sink using a 7/16"
open end wrench. See Figure F.18.

9. Remove the four mounting screws
that fasten the rectifier assembly to
the lift bail assembly.

a. Note the placement of the

arrangement of the insulating
materials on the mounting
screws for re-assembly. See
Figure F.19.

FIGURE F.18 - Output Rectifier Bridge
Assembly removal.

INSULATION

FIGURE F.19 - Mounting screw insu­lating material arrangement.

NOTE: If further disassembly is
required, see

Replacement Procedure
Mounting Instruction

SCR Removal and

and

Diode

.

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IDEALARC CV-300

F-35

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-35

MATERIALS NEEDED:

1/2" Open end wrench.
Lincoln E1868 (Dow Corning 340) Heat Sink Compound.
"Slip" type torque wrench.

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IDEALARC CV-300

F-36

TROUBLESHOOTING & REPAIR

F-36

MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS (CONT’D)

PROCEDURE

1. Loosen the appropriate diode nut
and remove the diode that is to be
replaced.

2. Clean the area on the heat sink
around the diode mounting surface
using a putty knife, or similar tool,
DO NOT SCRATCH THE DIODE
MOUNTING SURFACE.

3. Polish each heat sink's mounting
surface using NO. 000 fine steel
wool. Wipe surface clean with a lint
free cloth or paper towel.

4. Inspect the mounting surfaces of
each new diode. Remove all burrs
and wipe clean. Do not use steel
wool or any abrasive cleanser on
the diode mounting surface.

5. Apply a thin (0.0003" to 0.0007")
uniform layer of E1868 (Dow
Corning 340) heat sink compound to
the heat sink mounting surface.

DIODE STUD

SIZE

3/4 - 16
3/8 - 24
1/4 - 28

FOOT-

POUNDS

25-27
10±.5

INCH-

POUNDS

300-324

125+0/-5

22-25

a. Do not apply compound to diode

stud or mounting threads.

b. The diode threads must be

clean and free of defects so that
the nut can be finger tightened
before applying torque. A "slip"
type torque wrench must be
used to tighten the diode nut.

6. Tighten the diode nuts to the specifi­cations in the following table.

a. The nuts for diodes with steel

studs are to be started by hand
and then torqued as per the fol­lowing table.

b. The nuts for diodes with copper

studs are to run on all the way
by hand then torqued as per the
following table.

c. Turn a minimum of 1/2 turn

more while torquing per the
table.

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IDEALARC CV-300

F-37

TROUBLESHOOTING & REPAIR

F-37

SCR REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

MATERIALS NEEDED:

NO.000 Fine Steel Wool.
Penetrox A-13 (Lincoln E2529) or Penetrox A.
7/16” Open end wrench.
Allen head type wrenches.

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IDEALARC CV-300

F-38

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (CONTINUED)

F-38

ANODE

PROCEDURE:

Note: Before disassembling the existing
rectifier, note which heat sink the outer
metal ring of the power SCR is mounted
towards. Also, note the positioning of
the gate lead of the SCR. Failure to
reinstall the new SCR in the same orien­tation as the original may result in sub­sequent damage to the new SCR and
other components of the welder. See
Figure 20.

GATE

CATHODE

3. Clean the area on the heat sink
around the SCR mounting surface.
Using a putty knife, or similar tool.
DO NOT SCRATCH THE SCR
MOUNTING SURFACE.

4. Polish each heat sink's mounting
surface using NO. 000 fine steel
wool. Wipe surface clean with a lint
free cloth or paper towel.

5. Inspect the mounting surfaces of
each new SCR.

a. Remove all burrs and wipe

clean. Do not use steel wool or
any abrasive cleanser on the
SCR mounting surfaces.

6. Apply a thin (0.001" to 0.003") layer
of PENETROX A-13 (L.E. CO.
#E2529) or PENETROX A, heat sink
compound, to each heat sink's SCR
mounting surface.

OUTER METAL

RING

Fig. F.20 -SCR

CAUTION

The unclamping and clamping proce­dure outlined below is critical for the
prevention of internal SCR damage.
Failure to follow this procedure may
result in subsequent damage of the
SCR. Handle all SCRs with care.

__________________________

1. Alternately loosen nuts 1/2 turn
each until heat sinks are loose.
Remove nuts and leaf spring. IT IS
RECOMMENDED THAT NEW
HARDWARE, LEAF SPRING AND
HOUSING BE USED FOR
REASSEMBLY.

a. Care must be used to prevent

foreign material contamination
of the SCR to heat sink junction.

7. Place the new SCR between the
heat sinks. Be sure that the outer
metal ring of the SCR is facing
towards the same heat sink as the
old SCR's metal ring. Be sure that
the roll pin of the heat sink engages
the "hole" in the SCR. The SCR con­tact surfaces must sit flat against
both heat sink surfaces.

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2. Remove the old SCR.

IDEALARC CV-300

F-39

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (CONTINUED)

F-39

8. Go to procedure that matches cap
screws. NOTE WHICH THREAD IS
ON YOUR CAP SCREWS BEFORE
PROCEEDING TO THE ASSEM­BLY PROCEDURE. Two different
designs of leaf springs and housings
have been used to clamp the SCR
to the rectifier. The two different
designs can be identified by the size
of the leaf spring. One design uses
a 1/2 inch wide leaf spring and the
other uses a 5/8 inch wide spring.
The different designs require differ­ent assembly and clamping proce­dures. The assembly procedure will
be different depending upon the
thread on the cap screws. A 1/4-28
thread requires a different tightening
procedure than a 1/4-20 thread.

PROCEDURE FOR THE 1/2
INCH WIDE SPRING

1. Place a piece of sleeving around
each bolt.

3. Insert bolts and leaf spring into the
plastic housing.

4. Insert clamp assembly thru heat
sinks. Install nuts. Tighten clamp
nuts equally on bolts until finger
tight. (See Figure F.22. Heat sinks
may not be exactly as pictured.)

SLEEVING

HEAT SINK

LEAF

SPRING

S.C.R.

1/4-28 OR 1/4-20

CAP SCREW

2. Insert bolts thru the leaf spring.
Orient the leaf spring so that it's
ends are curved upward toward the
bolt heads. See figure F.21.
Pressing on the bolt heads should
produce a "rocking" motion of the
spring in its housing. If the spring
does NOT rock it is installed upside
down. Remove the spring and turn
it over. Check for "rocking" motion.
See Figure F.21.

SPRING CURVATURE

EXAGGERATED

1/2"

HOUSING

HEAT SINK

HEX NUT

PLAIN WASHER

Fig. F.22 - Clamp Assembly.

5. Re-inspect the SCR for proper seat­ing.

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Fig. F.21 - 1/2" Wide Leaf Spring

IDEALARC CV-300

F-40

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (CONTINUED)

F-40

CLAMPING PROCEDURE FOR
1/4-28 BOLTS.

Note: This procedure can only be used
with 1/4-28 bolts.

Do not use bolts with any other type
thread or new SCR will be damaged.

Do not over tighten cap screws. The leaf
spring will apply the required clamping
force to the SCR.

1. Do not turn the nuts. While holding
the nuts stationary, turn the cap
screws only with the following pro­cedure.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/4 turn.
STOP.

6. Assembly now has the proper
clamping force.

7. Perform the

Active SCR Test

.

5. Tighten second cap screw 1/2 turn.

6. Tighten first cap screw 1/4 turn.

7. Assembly now has proper clamping
force.

8. Perform the

Active SCR Test.

CLAMPING PROCEDURE FOR
1/4-20 BOLTS.

Note: This procedure can only be used
with 1/4-20 bolts.

Do not use bolts with any other type
thread or new SCR will be damaged.

Do not over tighten cap screws. The leaf
spring will apply the required clamping
force to the SCR.

1. Do not turn the nuts. While holding
the nuts stationary, turn the cap
screws only with the following pro­cedure.

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2. Tighten first cap screw 1/4 turn.

IDEALARC CV-300

F-41

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (CONTINUED)

PROCEDURE FOR THE 5/8
INCH WIDE SPRING

1. Place a piece of sleeving around
each bolt.

2. Insert bolts thru the leaf spring. The
leaf spring is flat so the orientation of
the leaf spring does not matter.

HEAT SINK

STEEL

PRESSURE

PAD

F-41

SLEEVING

LEAF

SPRING

3. Place the steel pressure pad in the
housing with the 1/8 inch wide
standoff facing up. See Figure F.23.

STEEL PRESSURE PAD

HOUSING

Figure F.23 - Housing and Pressure
Pad for 5/8" Wide leaf spring.

4. Insert bolts and leaf spring into plas­tic housing being sure that the steel
pressure pad remains in position.
Pressing on the bolt heads should
produce a rocking action of the
spring in it's housing.

5/8"

S.C.R.

1/4-28 OR 1/4-20

CAP SCREW

HOUSING

HEAT SINK

HEX NUT

PLAIN WASHER

Figure F.24 - Clamp Assembly.

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5. Insert clamp assembly thru heat
sinks. Install nuts. Tighten clamp
nuts equally on bolts until finger
tight. Be sure that the leaf spring is
not cocked in the housing. See
Figure F.24. Heat sinks may not be
exactly as pictured.

6. Re-inspect the SCR for proper seat­ing.

IDEALARC CV-300

F-42

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (CONTINUED)

PROCEDURE FOR CLAMPING
1/4-28 BOLTS.

3 Tighten second cap screw 1/2 turn.

F-42

Note: This procedure can only be used
with 1/4-28 bolts.

Do not use bolts with any other type
thread or new SCR will be damaged.

Do not over tighten cap screws. The
leaf spring will apply the required clamp­ing force to the SCR.

1. Do not turn the nuts. While holding
nuts stationary, turn the cap screws
only with the following procedure.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/2 turn.

6. Tighten first cap screw 1/2 turn.

4. Tighten the first cap screw 1/2 turn.

5. Tighten the second cap screw 1/4
turn.

6. Tighten the first cap screw 1/8 turn.

7. Tighten the second cap screw 1/8
turn.

8. Assembly now has the proper
clamping force.

9. Perform the

Active SCR Test

.

7. Tighten second cap screw 1/4 turn.

8. Assembly now has the proper
clamping force.

9. Perform

Active SCR Test

.

CLAMPING PROCEDURE FOR
1/4-20 BOLTS.

Note: This procedure can only be used
with 1/4-20 bolts.

Do not use bolts with any other type
thread or new SCR will be damaged.

Do not over tighten cap screws. The
leaf spring will apply the required clamp­ing force to the SCR.

1. Do not turn the nuts. While holding
the nuts stationary, turn the cap
screws only with the following pro­cedures.

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2. Tighten first cap screw 1/4 turn.

IDEALARC CV-300

F-43

TROUBLESHOOTING & REPAIR

FAN MOTOR AND FAN REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-43

MATERIALS NEEDED

5/16" Nutdriver.
3/8" Nutdriver.
3/8" Open end wrench.
Wire cutters.
Allen wrench.

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IDEALARC CV-300

F-44

TROUBLESHOOTING & REPAIR

FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED)

PROCEDURE

1. Disconnect main AC input power to
the machine.

2. Remove the Case Roof and Sides.

3. Remove the three screws from the
bottom of the Case Back Panel
using a 5/16" nutdriver. See Figure
F.25.

4. Remove the two screws that attach
the reconnect panel to the Case
Back Panel. See Figure F.25.

5. Remove that Case Back Panel.

6. Label and cut the fan motor leads.

F-44

7. Remove the four nuts, washers, and
lock washer which attach the fan
motor to the fan bracket. See figure
F.25.

8. Remove the fan motor and blade
assembly carefully.

9. Remove the fan blade from the
motor shaft using a Allen wrench.

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FIGURE F.25 - Fan Motor removal.

IDEALARC CV-300

F-45

TROUBLESHOOTING & REPAIR

CENTER ASSEMBLY REMOV AL AND REPLACEMENT

WARNING

Service and repair should be performed only by Lincoln Electric factory trained per­sonnel. Unauthorized repairs performed on this equipment could result in danger to
the technician or the 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.

If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call [phone] or [phone] (WELD).

_____________________________________________________________

F-45

MATERIALS NEEDED

5/16" Nutdriver.
3/8" Nutdriver.
1/2" Open end wrench.
9/16" Open end wrench.
3/4" Socket wrench.
Wire cutters.
Wiring diagram.

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IDEALARC CV-300

F-46

TROUBLESHOOTING & REPAIR

CENTER ASSEMBLY REMOVAL AND REPLACEMENT (CONTINUED)

F-46

PROCEDURE

1. Disconnect main AC input power
input leads to the machine.

2. Remove the Case Roof and Sides
using a 5/16" nutdriver and 3/8" nut­driver.

3. Disconnect the leads that run from
the reconnect panel to the ON/OFF
POWER SWITCH.

a. Pull all leads out through the lift

bail assembly.

4. Remove all the Molex plugs from the
control board and the snubber
board.

5. Disconnect all leads from the circuit
breakers and switches that could
hamper the removal of the Center
Assembly.

12. Disconnect leads #204D and 224A
connected to the resistor R1.

13. Attach a lifting device to the Center
Assembly Lift Bail.

a. DO NOT LIFT THE CENTER

ASSEMBLY FROM THE
MACHINE. This is to support

the Center Assembly so you can
remove the mounting bolts.

14. Remove the four mounting bolts that
attach the Center Assembly to the
Base Assembly using a 9/16" open
end wrench and a 3/4" socket
wrench. See Figure F.26.

15. Lift the Center Assembly carefully
from the machine.

a. Clear or cut any leads or cable

ties that hamper the removal of
the Center Assembly.

6. Remove any line connectors from
the 14 pin amphenol connector.

a. On some codes, the 14 pin

amphenol connector may have
to be removed.

7. Remove the choke leads from the
negative output terminals. See
wiring diagram.

8. Remove the heavy positive lead
from the positive output terminal.
See wiring diagram.

9. Label and cut the fan motor leads
and clear leads for easy removal.

10. Remove the four screws attaching
the reconnect panel to the Base
Assembly using a 5/16" nutdriver.

11. Remove the two screws attaching
the reconnect panel to the Case
Back Panel.

Fig. F.26 - Removal of Mounting Bolts

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a. The reconnect panel can be

removed with the Center
Assembly.

IDEALARC CV-300

F-47

TROUBLESHOOTING & REPAIR

F-47

RETEST AFTER REPAIR

Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could
affect the machine’s electrical characteristics or if any electrical components are repaired or replaced, the machine
must be retested.

INPUT IDLE AMPS AND WATTS

208/3/60
230/3/60
460/3/60
575/3/60

OPEN CIRCUIT VOLTAGE

Mode Open Circuit Volts

Maximum

Normal Range

Auxiliary Output (#31 - #32)

Auxiliary Output (#41 - #42 (#32A))

OUTPUT LOAD READINGS

Maximum Idle AmpsInput Volts/Hertz

11

10

5
4

Maximum Idle Watts

1000 watts
1000 watts
1000 watts
1000 watts

55 VDC

10-43 VDC

112/119 VAC

39/42 VAC

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Minimum

Maximum

AmpsOutput Control Setting

40-50

410

IDEALARC CV-300

Volts

1-7 VDC

36 VDC Minimum

ELECTRICAL DIAGRAMS

TABLE OF CONTENTS

- ELECTRICAL DIAGRAMS SECTION -

ELECTRICAL DIAGRAMS SECTION ...................... Section G

ELECTRICAL DIAGRAMS SECTION ...................... Section G

WIRING DIAGRAM........................................................G - 2

WIRING DIAGRAM........................................................G - 2

Codes 10181, 10180, 9940, 9939

Codes 10181, 10180, 9940, 9939

WIRING DIAGRAM........................................................G - 4

WIRING DIAGRAM........................................................G - 4

Codes 9520, 9486

Codes 9520, 9486

WIRING DIAGRAM........................................................G - 6

WIRING DIAGRAM........................................................G - 6

Code 9456

Code 9456

G2518 CONTROL PC BOARD SCHEMATIC ..............G - 8

L8930 CONTROL PC BOARD SCHEMATIC ...............G - 8

G2003 CONTROL PC BOARD SCHEMATIC .............G - 10

L8873 CONTROL PC BOARD SCHEMATIC..............G - 10

M15892 METER PC BOARD SCHEMATIC................G - 12

M15893 METER PC BOARD SCHEMATIC................G - 12

S19687 SNUBBER PC BOARD SCHEMATIC............G - 14

M15370 SNUBBER PC BOARD SCHEMATIC ...........G - 14

L8930 CONTROL PC BOARD LAYOUT.....................G - 16

L8930 CONTROL PC BOARD LAYOUT.....................G - 16

L8873 CONTROL PC BOARD LAYOUT.....................G - 18

L8873 CONTROL PC BOARD LAYOUT.....................G - 18

M15893 METER PC BOARD LAYOUT.......................G - 21

M15893 METER PC BOARD LAYOUT.......................G - 20

M15370 SNUBBER PC BOARD LAYOUT..................G - 23

M15370 SNUBBER PC BOARD LAYOUT..................G - 22

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IDEALARC CV-300

NOTES

G-1G-1

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IDEALARC CV-300

G-2

208/230/460 INPUT VOLTAGES

RECONNECT
PANEL

B

A

TO S1 LINE SWITCH

208V 230V 460V

5

6

C

8

7

9

2

3

1

F

E

2 3 1

230/460/575 INPUT VOLTAGES

RECONNECT
PANEL

TO S1 LINE SWITCH

230V 460V 575V

8

9

7

6

5
E

F

2

31

2 3 1

4

D

8

4
D

WIRING DIAGRAM CV-300 (60Hz)

INPUT SUPPLY
LINES

UW

L1 L3

13

S1
LINE
SWITCH

RECONNECT
PANEL

C

B

9

3

A

TO S1 LINE SWITCH

RECONNECT
PANEL

9

6
F

TO S1 LINE SWITCH

V

L2

2

*

TO A SYSTEM GROUND PER

*

NATIONAL ELECTRICAL CODE.

4

6

5

8

7

2

1

D

F

E

2 3 1

8

8

7

4

5
E

D

2

31

2 3 1

ELECTRICAL DIAGRAMS

WIRING DIAGRAM FOR CODES 10181, 10180, 9940, 9939

SNUBBER/BYPASS

P.C. BOARD

8
2
3

J5

4

1

7

213B

CONTROL
P. C. BOARD

J10

4

J1

2
1

3
4

8

J2

9
6

J3

10

2
3
7
5

1

J4

6

J5

5

218

224B

219

1

2

214B

8

224B

3

277

7

276

4

NC

2

275

5

2

2

1

4

6

6

1
4
3

211

5

212

2

VOLTS / AMPS

(SHOWN IN "VOLTS" POSITION)

ELECTRICAL SYMBOLS
PER E1537

CONNECTOR CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P. C. BOARD)

2 PIN

J10

4 PIN

J1

J7

C1-C4 31,000 MFD EACH

N.A. WIRING VIEWED FROM REAR OF POTENTIOMETER
N.B. TAP LEADS A, B, AND C APPEAR ON THE TOP PRIMARY COILS

OF 208/230/460V MACHINES ONLY.

RECONNECT
PANEL

3

C
6

N.B.

RECONNECT
PANEL

B

A

TO S1 LINE SWITCH

RECONNECT
PANEL

TO S1 LINE SWITCH

9
F

2
B

5
8

E

1
A

4
7

D

4

5

6

C

8

7

9

2

3

1

D

F

E

2 3 1

8

9

6
F

8

7

4

5
E

D

2

31

2 3 1

MAIN TRANSFORMER

204C

224A

204A

213B

202

224A

G2

G1

203
200

201

205
206

NC

221
222
223
224

G3

215

3

12

2

11

1

10

s
12V

O2 TOP

s
12V

O1 TOP

31B

s

42V

O1 TOP

s

O3 TOP

58V

O3 BOT.

58V

s

223

222

221

41A

42A

SCR3

D3

SCR2

D2

SCR1

D1

CB1

G3

G2

G1

41

42
10A

CIRCUIT

BREAKER

33A

FAN

31A

204D
204C

204A

224

33

31B

D5

115V

204D

7.5 OHM
220 W

+
C1

+

C2
+

C3

+

C4

D4

224B

SECONDARY
THERMOSTAT

L1

32

CB2

5A

CIRCUIT

BREAKER

31

R1

CLEVELAND, OHIO U.S.A.

213
214

400 A. 50mV

SHUNT

+

-

L1 CHOKE

214B

LOCAL/REMOTE SWITCH
(SHOWN IN LOCAL POSITION)

S4

277

276

N.A.

207
208
209
210

S2

6 PIN

J4

376

377

77

76

10K
OUTPUT
CONTROL

1
2

J7

3

METER

4

P.C.
BOARD

N.A.

8 PIN

J2

213A

J5

214

376

213B

CW

213

377

R2

10 PIN

J3

+

-

-

77

77

76

75

213A

S3

21

WIRE FEEDER
VOLTMETER
SWITCH

242

31
32
41
42

WIRE

FEEDER

RECEPTACLE

214A

WIRE

FEEDER

H

VOLTMETER

E
F
G
C

C
D
N
J

115 VAC

A
I

42 VAC

K
L

B

GROUND

M

CUSTOMER
CONNECTIONS

6-18-93

L8927

G-2

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

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IDEALARC CV-300

IDEALARC CV-300

G-3

NOTES

G-3

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IDEALARC CV-300

G-4

1

2

3

TO

S1
LINE
SWITCH

RECONNECT PANEL

1

1

2

2

3

3

TO S1 LINE SWITCH

TO A SYSTEM GROUND PER

*

NAT

IONAL ELECTRICAL

208/230/460 INPUT VOLTAGES

RECONNECT
PANEL

B

C

A

1

7

D

E

F

4

8

2

5

3

9

6

208V

230/460/575 INPUT VOLTAGES

7

D

4

8

E

5

9

F

6

230V

CODE

1
2

3

TO

S1
LINE
SWITCH

RECONNECT PANEL

1

1

2

2

3

3

TO S1 LINE SWITCH

460V

INPUT SUPPLY

LINES

L3

L3

S1

S1
LINE

LINE
SWITCH

SWITCH

RECONNECT
PANEL

B

C

A

1

7

D

E

F

4

8

2

5

3

9

6

230V 460V

7

D

4

8

E

5

9

F

6

L2

L2

2

3

1

2

3

TO

S1
LINE
SWITCH

RECONNECT PANEL

1

1

2

2

3

3

TO S1 LINE SWITCH

575V

D

E

1

*

RECONNECT
PANEL

C

F

D

4

E

5

F

6

ELECTRICAL DIAGRAMS

WIRING DIAGRAM FOR CODE 9520, 9486

RECONNECT PANEL

204C

N.B.

1

A

3

4

L1

L1

ˇ˜ð 7/64 ×@7

7

D

10

2
B

5

8

E

3
C

2

11

1

6
9

F

12

12V

12V

66V

B

A

1

7

2

4

8

3

9

5

6

7

8

9

42V

MAIN
TRANSFORMER

SCR3

223

G3

D3

SCR2

G2

D2

222

204D
204C

SCR1

204A

221

O1

O2

O3

41

O1

G1

D1

224

31A

31

ELECTRICAL SYMBOLS
PER E1537

FAN

D5

33A

204D

7.5 OHM
220 W

+

+

D4

SECONDARY
THERMOSTAT

L1

33

10A

CIRCUIT

BREAKER

+
C1

C2
+

C3

C4

224B

CB1

221
222
223
224

R1

224A

224A

G2

G3

204A

G1

213B
200

201

202

203

215

205
206
NC

32

32A

2 PIN

J10

SNUBBER/BYPASS

P.C. BOARD

8

2

3

J5

6

4

J5

1

7

213B

224B

CONTROL
P. C. BOARD

1

J10

2

4

2

J1

8

1

3

4
6

10
8

3
7

4

J2

5

1

J3

9

6

2
3

6

7

1

5

4

1

J4

3

5
2

CONNECTOR CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P. C. BOARD)

4 PIN

J1

N.A. SWITCH & POTENTIOMETER WIRING
VIEWED FROM REAR OF SWITCH.

N.B. TAP LEADS A, B, AND C APPEAR ON TOP
PRIMARIES FOR 208/230/460 MACHINE ONLY.

213
214

5

6 PIN
J4
J7

218

400 A. 50mV

SHUNT

L1 CHOKE

219

214B

N.A.

J8A P8A

44

214B
224B

33

277

2

2

276

11

275

2
4

207
208
209
210

211
212

(SHOWN IN "VOLTS" POSITION)

S2

VOLTS / AMPS

8 PIN

J2
J5

C1-C4 31,000 MFD

213A

377

376

375

OUTPUT
CONTROL

1

2

J7

3

4

N.A.

10 PIN

213A

213B

214

214B

214A

WIRE FEEDER
VOLTMETER SWITCH
S3

21

CW

10K

R2

N.A.

METER
P.C.
BOARD

J3

213

476

+

-

-

475

32A

477

31
32

41

P9

TO

1

OPTIONAL

2

POWER
SOURCE

3

REMOTE

4

KIT

WIRE

H

VOLTMETER

E
F
G
C
D
N
J
A
K

I
L
B
M

WIRE

FEEDER

RECEPTACLE

FEEDER

115 VAC

42 VAC

GROUND

CUSTOMER
CONNECTIONS

8236

L

SHT.

NO.

SUP'S'D'G

L7970

WIRING DIAGRAM (60 HZ)

CV-300

REF.

TYPE

EQUIP.

SUBJECT

F.V. 3-2-90

CHK

NONE

DATE

SCALE

CLEVELAND, OHIO U.S.A.

DG/BS

THE LINCOLN ELECTRIC CO.

DR

12-20-90H

G-4

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

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L

8236

IDEALARC CV-300IDEALARC CV-300

G-5

NOTES

G-5

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IDEALARC CV-300

G-6

ELECTRICAL DIAGRAMS

WIRING DIAGRAM FOR CODE 9456

G-6

220V-380V-440V INPUT

INPUT
SUPPLY
LINE

L1

L2

L3

S1
LINE
SWITCH

440V/50/60HZ

INPUT
SUPPLY
LINE

380V/50/60HZ

INPUT
SUPPLY
LINE

220V/50/60HZ

RECONNECT PANEL

12

2

10

3

11

*

S1
LINE
SWITCH

L1

L2

L3

*

S1
LINE
SWITCH

L1

L2

L3

*

1

7

4

8
9

5

6

RECONNECT
PANEL

12

1

10

2

11

RECONNECT
PANEL

12

1

10

2

11

230V-460V INPUT

INPUT
SUPPLY

1

LINE

460V/60HZ

INPUT
SUPPLY
LINE

L1

L2

L3

L1

L2

L3

4
7

10

2

5
8

11

3

6

9

12

7

4

8

5

3

9

6

RECONNECT PANEL

1

2

3

*

S1
LINE
SWITCH

RECONNECT PANEL

1

2

3

4

7

5

8

6

9

7

8

9

10

11

12

4

5

6

3

1

4
7

2

2

5

8

3

6

9

1

12V

O1

12V

O2

*

O3

S1

6

7

4

8

5

3

9

LINE
SWITCH

230V/60HZ

MAIN TRANSFORMER

66V

42V

O1

223

222

221

SCR3

G3

D3

SCR2

G2

D2

204D

204C

SCR1

204A

G1

D1

224

FAN

31A

31

41

D5

33A

204D

7.5 OHM
220 W

+

C1

+

C2
+

C3
+

C4

D4

SECONDARY
THERMOSTAT

L1

33

CB1

10A

CIRCUIT

BREAKER

R1

224B

204C

224A

224A

G2

G3

204A

G1

213B
200

201

202

203

215

205
206

NC

32

32A

221
222
223
224

4
2

1

3

4
6

10

8

9
2
3

7
5

SNUBBER/BYPASS

P.C. BOARD

8
2
3

J5

4

J5

1

7

213B

224B

CONTROL
P. C. BOARD

1

J10

2

J1

8
3
7

4

J2

5

1

J3

6

6

1

1

4

J4

3

5
2

6

213
214

5

218

214B
224B

277

276

275

2
4

211
212

(SHOWN IN "VOLTS" POSITION)

400 A. 50mV

L1 CHOKE

219

214B

N.A.

J8A P8A

44

33

2

11

207
208
209
210

VOLTS / AMPS

2

S2

SHUNT

213A

377

376

375

OUTPUT
CONTROL

1
2
3
4

N.A.

213A

213B

214

214B

214A

WIRE FEEDER

VOLTMETER SWITCH
S3

21

CW

10K

R2

N.A.

J7

METER
P.C.
BOARD

213

+

-

-

475

476

477

31
32

32A

41

P9

TO

1

OPTIONAL

2

POWER
SOURCE

3

REMOTE

4

KIT

WIRE

H

VOLTMETER

E
F
G
C
D
N
J
A
K

I

L
B
M

WIRE

FEEDER

RECEPTACLE

FEEDER

115 VAC

42 VAC

GROUND

CUSTOMER
CONNECTIONS

7970

M15567

WIRING DIAGRAM

CV-300 & CV 400-I

1-12-89

2-1-91D

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

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7970

TO A SYSTEM GROUND PER

*

NAT

IONAL ELECTRICAL

CODE

ELECTRICAL SYMBOLS
PER E1537

2 PIN

J10

CONNECTOR CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P. C. BOARD)

4 PIN

J1

6 PIN

J4

J7

C1-C4 31,000 MFD

N.A. SWITCH & POTENTIOMETER WIRING
VIEWED FROM REAR OF SWITCH.

8 PIN

J2
J5

10 PIN

J3

IDEALARC CV-300IDEALARC CV-300

G-7

NOTES

G-7

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IDEALARC CV-300

G-8

CONTROL

PHASE
RELATION
WINDING

9

X3

10

4

X3

LM224

11

FEEDBACK

CURRENT
FEEDBACK

G

2518

POT

8

+5.5V+8.2V

C22

MC68705R3CP

OUTPUT

7

4

5

6

10

4

X2

1

J2

8

THERMOSTAT

J10

1

J10

2

ELECTRICAL DIAGRAMS

G-8

L8930 CONTROL PC BOARD SCHEMATIC

+5.5V

+5.5V

+5.5V+8.2V

J2

J2

R29
10K

J2

2.21K

R30

J3

J3

R48

R49

D19

D20

C6

0.1
50V

ZERO

CROSS

WINDING

+5.5V

C20

1.00K

10K

C18

C17

.02

.02

600V

600V

D31

R63
475

100K

R73

100K

R74

D30

R38

56.2K

4.75K

R34

C25

J3

8

J3

9

C8

LINE
VOLTAGE
MONITOR

R39

RELATION

R57

4.75K

+5.5V

4.75K

R37

C23

R61
475

R50
475
R51
475

22.1K

PHASE

D1

D2

D17

D18

C27

D3

D4

15.0K

R82

AMMETER

AMPLIFIER

12

13

D32

D22

D35

D34

+5.5V

4.75K

R36

Q8
200mA
30V

D5

4.75K

R78

1.00K

R59

2

3

C29
.0047
50V

14

X3

R52

39.2K

C11

ZERO

CROSS

R47

4.75K

C1

0.1
50V

R65

15.0K

C28
.0047
50V

X3

R53

1.00K

+5.5V

+5.5V

4.75K

R79

Q1
200mA
30V

C19

0.1
50V

1

SHORT CIRCUIT

AMPLIFIER

D26

C21

12.1K

R28

D21

D29

D27

D28

J3

7

J3

3

+5.5V

CAPACITOR

+5.5V

D23

C12

1.0
35V

ANALOG

MULTIPLEXING

OF CONTROL

LINE

VOLTAGE

R58

2.7
1W

C26

BANK

FEEDBACK

3

2

1.00M

R24

POT AND

MONITOR

+8.2V

C2
35V

1000

R66
10K

J2

J2

+VS

R80

POWER

SUPPLIES

IN

475

DZ1

8.2V
500mW

+5.5V

56.2K

R69

47.5K

R68

C7

1.00K

R26

10K

R27

475

R60

D33

D36

X1

OUT

GND

SHORT
DETECT

6

X3

5

R70
100K

D13

10K

D14

C4

1.0

3.5795 MHz

C5

22p

100V

+5.5V

619

8.25KR13.92K

R6

C3

1.0

30.1

35V

R81

NOTE:

RESISTORS MAY NOT BE PRESENT

7

D37

2.00K

1.00K

R3

R2

POWER SUPPLY
CALIBRATION

SOME OR ALL OF THESE

10K

R71

R4

+5.5V

D38

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.

35V

Y1

511

R5

10K

+5.5V

R56

R25

1.50K

R44

C16

16

2

5

6

15

21

18

17

24

19

+5.5V

8

7
4

1

20

23

13

3

11

12

PC7
RES
EXTAL
XTAL
PC6
PD3
PD6

PD5

PD0

PD7
TIMER
VPP

PD4

VSS

VCC
PD1
PC4
INT
PC2
PC3

MC68705R3CP

PA7
PA6

X2

PA4

PA5
PA3
PA2
PA1
PA0
PB6

PB7

PC5

PB4

PB5
PB0
PB1
PB2
PB3
PC1
PD2
PC0

+5.5V

J4

1

BD. POWER

J4

6

DATA

CLOCK

BD. COMMON

J4

J4

+VS

J6

+5.5V

J6

J6

J6

5

2

R8
475

4

11

12

3

METER
BOARD

VOLT/AMP SW.

PILOT LED

+5.5V

4.75K

R45

+VS

30.1

+5.5V

R21

2.21K

R11

C13

.1

50V

10K

R41

+5.5V

C14
50V

R42

LED1

+5.5V

4.75K

R46

10K

C15

.1

50V

R43
10K

DZ5
3V
500mW

100K

R40

2

J3

1

J3

4

J3

3 SCR/6 SCR

5

J3

6-18-93

+5.5V

2.21K

R10

.1

+5.5V

R9

+5.5V

4.75K

R33

Q9
200mA
30V

WYE/DELTA

R20

2.21K

+VS

1.00K

R17

Q4

R16

2.21K

2.21K

R12

2.21K

200mA
30V

+VS

R13

C9

10K

R32

THE LINCOLN ELECTRIC CO.

M.J.H.

DR.

30.1

R22

1.00K

Q7
195mA

DZ6
18V

1W

DZ8
18V

1W

+VS

DZ4

5.1V
500mW

DZ2
18V

1W

1A, 400V

R18

R14

3300
5W

R7

R31
3300

5W

MFD

60V

30.1

Q5
195mA
60V

30.1

Q3
195mA
60V

.022/50V

(

1/4W

(UNLESS OTHERWISE SPECIFIED)

Q6
200mA
30V

1.00K

Q2
200mA
30V

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
RESISTORS = Ohms (
DIODES =

FILE G2518.1AA

CLEVELAND, OHIO U.S.A.

SCALE

DATE

6-2-92

NONE

R75

DZ3
27V
1W

D11

30.1

R76

DZ7
27V
1W

D9

D10

30.1

R77

DZ9
27V
1W

D7

D8

J2

D6

J2

D15

C10
.02
600V

UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)

EQUIP.
TYPE

SUBJECT

OBS

CHK.

1.00K

D12

R23

1.00K

R19

1.00K

R15

1

6

SUP'S'D'G.

J1

3

GATE 1

BRIDGE

J1

1

COMMON

J1

4

GATE 2

J1

2

GATE 3

2-4 SWITCH

LAST NO. USED

R-

_
_

C-

_

D-

LABELS

SUPPLY

VOLTAGE NET

POWER SUPPLY SOURCE POINT

COMMON CONNECTION

FRAME CONNECTION
EARTH GROUND CONNECTION

CV WELDERS

SCHEMATIC, CONTROL

SHT.

G

2518

NO.

J4

4

J4

3

D24

D25

+5.5V

10K

R72

J6

9

40

J6

39

10

J6

38

5

J6

37

8

J6

36

7

J6

35

6

J6

34

2

J6

33

1

31

30

29

14

32

25

26

27

28

10

22

9

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for
reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

IDEALARC CV-300IDEALARC CV-300

G-9

NOTES

G-9

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

IDEALARC CV-300

G-10

CONTROL

PHASE
RELATION
WINDING

9

X3

10

4

X3

LM224

11

FEEDBACK

CURRENT
FEEDBACK

G

2003

POT

8

+5.5V+8.2V

C22

MC68705R3CP

OUTPUT

7

4

5

6

10

4

X2

1

J2

8

THERMOSTAT

J10

1

J10

2

ELECTRICAL DIAGRAMS

G-10

L8873 CONTROL PC BOARD SCHEMATIC

+5.5V

+5.5V

+5.5V+8.2V

J2

J2

R29
10K

J2

2.21K

R30

J3

J3

R48

R49

D19

C6

0.1
50V

ZERO

CROSS

WINDING

+5.5V

C20

1.00K

10K

C17

C18

.02

.02

600V

600V

D31

C8

D30

12.1K

R28

LINE
VOLTAGE
MONITOR

D21

R38

56.2K

D29D20

D27

D28

J3

7

J3

3

R63
475

+5.5V

R73

R74

22.1K

R39

+5.5V

4.75K

R34

8

9

100K

100K

PHASE

RELATION

R57

4.75K

C25

D1

J3

J3

D2

+5.5V

4.75K

D17

R37

C23

D18

R61
475

475

R50
R51
475

C27

D3

D4

15.0K

R82

AMMETER

AMPLIFIER

12

13

4.75K

R36

Q8
200mA
30V

D5

4.75K

ZERO

R78

CROSS

C1

0.1

1.00K

50V

R59

2

3

C29
.0047
50V

14

R53

X3

1.00K

R52

39.2K

D35

C11

R47

4.75K
C19

0.1
50V

R65

15.0K

C28
.0047
50V

1

X3

SHORT CIRCUIT

AMPLIFIER

+5.5V

D26

C21

D32

D22

D34

+5.5V

4.75K

R79

Q1
200mA
30V

CAPACITOR

+5.5V

D23

C12

1.0
35V

MULTIPLEXING

ANALOG

OF CONTROL

VOLTAGE

LINE

R58

2.7
1W

C26

BANK

FEEDBACK

3

2

1.00M

R24

POT AND

MONITOR

+8.2V

C2
35V
1000

R66
10K

J2

J2

SUPPLIES

+VS

IN

475

R80

DZ1

8.2V
500mW

+5.5V +5.5V

56.2K

R69

47.5K

R68

1.00K

R26

10K

R27

475

R60

D33

POWER

D36

X1

GND

6

X3

5

+5.5V

OUT

SHORT
DETECT

7

R70
100K

C7

D13

10K

D14

C4

1.0

3.5795 MHz

C5

22p

100V

619

8.25KR13.92K

R6

C3

1.0

30.1

35V

R81

NOTE:

RESISTORS MAY NOT BE PRESENT

D37

2.00K

1.00K

R3

R2

POWER SUPPLY
CALIBRATION

SOME OR ALL OF THESE

R71
10K

R4

D38

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.

35V

Y1

511

R5

10K

+5.5V

R56

R25

1.50K

R44

C16

16

PC7
RES
EXTAL
XTAL
PC6
PD3
PD6

PD5

PD0

PD7
TIMER
VPP

PD4

VSS

VCC
PD1
PC4
INT
PC2
PC3

MC68705R3CP

PA7
PA6

X2

PA4

PA5
PA3
PA2
PA1
PA0
PB6

PB7

PC5

PB4

PB5
PB0
PB1
PB2
PB3
PC1

PC0

PD2

2

5

6

15

21

18

17

24

19

+5.5V

8

7

4

1

20

23

13

3

11

12

+5.5V

J4

1

BD. POWER

J4

6

DATA

CLOCK

BD. COMMON

J4

J4

+VS

J6

+5.5V

J6

J6

J6

5

2

4

11

12

3

R8
475

METER
BOARD

VOLT/AMP SW.

PILOT LED

4.75K

R45

+VS

30.1

+5.5V

2.21K

R11

C13

.1

50V

R41
10K

+5.5V

C14
50V

R42

LED1

+5.5V+5.5V

4.75K

R46

10K

C15

.1

50V

R43
10K

DZ5
3V
500mW

100K

R40

2

J3

1

J3

4

J3

3 SCR/6 SCR

5

J3

+5.5V

2.21K

R10

.1

+5.5V

R9

+5.5V

4.75K

R33

Q9
200mA
30V

WYE/DELTA

R20

2.21K

R16

2.21K

2.21K

R12

2.21K

9-11-92M

1.00K

R21

Q6
200mA
30V

+VS

1.00K

R17

Q4
200mA
30V

+VS

1.00K

R13

Q2
200mA
30V

C9

10K

R32

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
RESISTORS = Ohms (
DIODES =

THE LINCOLN ELECTRIC CO.

CLEVELAND, OHIO U.S.A.

M.J.H.

DR.

DZ2
18V

1W

DZ6
18V

1W

DZ8
18V

1W

+VS

DZ4

5.1V
500mW

1A, 400V

SCALE

DATE

R22

Q7
195mA
60V

30.1

R18

Q5
195mA
60V

30.1

R14

Q3
195mA
60V

3300
5W

R7

R31
3300

5W

MFD

.022/50V

(

1/4W

(UNLESS OTHERWISE SPECIFIED)

NONE

9-13-90

30.1

R75

DZ3
27V
1W

D11

30.1

R76

DZ7
27V
1W

D9

D10

30.1

R77

DZ9
27V
1W

D7

D8

J2

D6

J2

D15

C10
.02
600V

UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)

EQUIP.
TYPE

SUBJECT

CHK.

D12

1.00K

R19

1.00K

R15

1

6

J1

1.00K

R23

J1

J1

J1

2-4 SWITCH

LABELS

CV CONTROL BOARD

SUP'S'D'G.

3

GATE 1

BRIDGE

1

COMMON

4

GATE 2

2

GATE 3

LAST NO. USED

R­C­D-

SUPPLY

POWER SUPPLY SOURCE POINT

COMMON CONNECTION

FRAME CONNECTION
EARTH GROUND CONNECTION

SCHEMATIC

82
29
38

VOLTAGE NET

SHT.
NO.

G

2003

J4

4

J4

3

D24

D25

+5.5V

10K

R72

J6

9

40

J6

39

10

J6

38

5

J6

37

8

J6

36

7

J6

35

6

J6

34

2

J6

33

1

31

30

29

14

32

25

26

27

28

10

22

9

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for
reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

IDEALARC CV-300IDEALARC CV-300

G-11

NOTES

G-11

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

IDEALARC CV-300

G-12

5

15892

ELECTRICAL DIAGRAMS

G-12

M15893 METER PC BOARD SCHEMATIC

M

+5V

Q1

D1

3.32K

R2

X5

6

C1

300mA
30V

475

R1

1
2
4
5
6
7
9

10

3

LED1

8

1
2
4
5
6
7
9

10

3

LED2

8

1
2
4
5
6
7
9

10

3

LED3

8

+5V IN

DATA

CLOCK

COMMON

98

X5

J7

2

J7

1

3

4

R25

J7

R26

J7

+5V

R27

+5V

3.01K

C5
330p
50V

R28

3.01K

1

C6
330p
50V

D2
1N914

R4

R3

3

4

5

6

10

11

12

13

X5

X5

2

12

3

X5

11

X5

4

R5

A

X1

Q

B

Q
Q

C

Q

D

E

Q
Q

F

Q

G

74HC164

10

R7

R6

A1
A2
CLK
R
Q

R9

R8

+5V

1

2

8

9

13

H

3

4

5

6

10

11

12

R11

R10

A

Q

B

Q
Q

C

Q

D

E

Q
Q

F

Q

G

R12

X2

74HC164

R13

A1
A2
CLK
R
Q

R14

R15

R16

R17

+5V

1

2

8

9

13

H

R18

R19

3

4

5

6

10

11

12

R21

R20

A

Q

B

Q
Q

C

Q

D

E

Q
Q

F

Q

G

R22

X3

74HC164

A1
A2
CLK
R
Q

R23

H

R24

+5V

1

2

8

9

13

+5V+5V

RESET 2

DATA 2

SET 2

VCC

Q2

N.C.

14

13

12

11

10

9

8

1

2

3

4

5

6

7

RESET 1
DATA 1
CLOCK 1
SET 1
Q1
/Q1
GND

CLOCK 2

X4

54HC74

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not available from
Lincoln Electric. This information is provided for reference only . Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator
or Technician. Improper PC board repairs could result in damage to the machine.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

14

X1

74HC164

7

C2

14

X2

74HC164

7

C3

14

X3

74HC164

7

14

X4

C4

54HC74

7

C7

X5

HEXINV

14

C8

7

NOTES :

N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE

WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.

4-30-93A

GENERAL INFORMATION

ELECTRICAL SYMBOLS PER E1537
CAPACITORS =
RESISTORS = Ohms (
DIODES =

NOTE: ALL UNMARKED RESISTORS = 100 OHMS

1A, 400V

MFD

(

.022/50V

1/4W

(UNLESS OTHERWISE SPECIFIED)

THE LINCOLN ELECTRIC CO.

CLEVELAND, OHIO U.S.A.

DR.

JCP

SCALE
DATE

NONE

01-06-89

UNLESS OTHERWISE SPECIFIED)

UNLESS OTHERWISE SPECIFIED)

EQUIP.
TYPE

SUBJECT

CHK.

IDEALARC CV-300IDEALARC CV-300

LABELS

CV WELDERS

METER P.C. BOARD SCHEMATIC

SUP'S'D'G.

LAST NO. USED

28

R­C-

8

D-

2

SUPPLY

VOLTAGE NET

POWER SUPPLY SOURCE POINT

COMMON CONNECTION

FRAME CONNECTION
EARTH GROUND CONNECTION

SHT.

15892

M

M

NO.

G-13

NOTES

G-13

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

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IDEALARC CV-300