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