Lincoln Electric CV-305 User Manual

IDEALARC

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For use with machines having Code Numbers: 11177 thru 11179

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation ...
and thoughtful operation on your
part. DO NOT INSTALL, OPER-

ATE OR REPAIR THIS EQUIP­MENT WITHOUT READING
THIS MANUAL AND THE SAFE­TY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

SVM191-A

April, 2009

®

CV-305

View Safety Info View Safety Info View Safety Info View Safety Info

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

SERVICE MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

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

____________________________________________________

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

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from 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.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.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.

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

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.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

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

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

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

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

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

___________________________________________________

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.

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2.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.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

Mar ‘95

IDEALARC® CV-305

ii ii

SAFETY

ELECTRIC SHOCK can kill.

3.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.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

3.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.

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

3.f.

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

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

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

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

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.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.

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

4.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
can be dangerous.

5.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

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven­tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized
steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

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.

vapors

to

5.d. 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.

5.e. 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.

5.f. Also see item 1.b.

Jan ‘09

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IDEALARC® CV-305

iii iii

SAFETY

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

the welding sparks from starting a fire.

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.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.

6.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).

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

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

6.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.

6.h. Also see item 1.c.

If this is not possible, cover them to prevent

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.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.

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

7.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.

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

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

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

7.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.

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

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

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

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

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Jan ‘09

IDEALARC® CV-305

iv iv

SAFETY

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.

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” CSA Standard
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
zones où l’on pique le laitier.

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

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IDEALARC® CV-305

I I

RETURN TO MAIN MENU

- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv

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

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

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

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

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

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

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

Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-511

IDEALARC® CV-305

A-1 A-1

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Stacking/Tilting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

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

Options/Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

TABLE OF CONTENTS - INSTALLATION SECTION

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IDEALARC® CV-305

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC CV-305

INPUT - THREE PHASE ONLY

Voltage, 60Hz

Current at Rated Output,

100% Duty Cycle

Code

Number

208/230/460 Volts

230/460/575 Volts

Duty Cycle

100% Duty Cycle

NEMA Class I (100)

Welding Current/Voltage Range

(Continuous)

50A/7V - 400A/37V

DC

Efficiency at 100% Load

75%

Idle Power

51/48/24 Amps

48/24/20 Amps

RATED OUTPUT

Amps

315

OUTPUT

Open Circuit Voltage

10-50

MISC. INFORMATION

Power Factor at 100% Load

.71

11177

11178

Volts at Rated Amperes

32.6

Auxiliary

42 Volts AC, 10 Amps
115 Volts AC, 5 Amps

( Both Circuit Breaker Protected)

Idle Current

575Volts input - 3Amps

460Volts input - 3.4Amps

230Volts input - 7Amps

208Volts input - 8Amps

Power

950W

PHYSICAL DIMENSIONS

Height Width Depth Weight

21.5 in. 19.7 in. 26.3 in.
(Lift bail, add 3.12 in)

546 mm 500 mm 668 mm 150 kg
(Lift bail, add 83 mm)

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IDEALARC® CV-305

330 lbs.

A-3 A-3

INSTALLATION

Read entire installation section before starting
installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

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

• Turn the Power switch on the CV-305 “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-305 grounding terminal
(located on the welder base near the reconnect panel) to a
good
electrical earth ground.

SELECT SUITABLE LOCATION

Place the welder 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 welder should be kept at a
minimum. Failure to observe these precautions can
result in excessive operating temperatures and
nuisance shut-downs. Idealarc CV-305 power sources
carry an IP21S enclosure rating. They are rated for use
in damp, dirty environments subject to occasional
falling water such as rain.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SUR­FACES.

Where there is a combustible surface directly under
stationary or fixed electrical equipment, the surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not more than 5.90”(150mm)
beyond the equipment on all sides.

------------------------------------------------------------------------

STACKING

INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the input
power is as specified on the welder nameplate.

Gain access to the input reconnect panel by removing
the right case side of the CV-300 (side nearest to the
Power switch.)

Have a qualified electrician connect the input leads to
L1, L2, and L3 of the input reconnect panel in accor­dance with the National Electrical Code, all local
codes, and the connection diagram located on the
inside of the right case side. Use a three phase line.

The frame of the welder must be grounded. A ground
terminal marked with the symbol located on the
base of the machine is provided for this purpose. See
the National Electrical Code for details on proper
grounding methods.

Fuse the input circuit with the recommended super lag
fuses. Choose an input and grounding wire size
according to local codes or use the following table.
"Delay type"
fuses. Using fuses or circuit breakers smaller than rec­ommended may result in "nuisance" tripping from
welder inrush currents even if not welding at high cur­rents.

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

Frequency

208/60

230/60

460/60

575/60

1

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit
breakers which have a delay in tripping action that decreases as the magni­tude of the current increases.

1

circuit breakers may be used in place of

Fuse

(Super Lag)

or Breaker

Size

70

60

40

40

Input

Ampere

Rating on

Nameplate

51

48

24

20

Type 75°C

Copper Wire

in Conduit
AWG (IEC)

Sizes

6 (16 mm2)

6 (16 mm2)

10 (6mm2)

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

8 (10mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

The CV-305 may be stacked three-high provided the
bottom machine is on a stable, hard, level surface. Be
sure that the two pins in the roof fit into the slots in the
base of the CV-305 above it.

TILTING

Do not place the machine on a surface that is inclined
enough to create a risk of the machine falling over.

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IDEALARC® CV-305

A-4 A-4

INSTALLATION

FIELD INSTALLED OPTIONS

For installation of compatible field installed options
(see the ACCESSORIES section of this manual and
refer to the instructions included with those options.

REQUIRED EQUIPMENT-CONTROL
CABLE CONNECTIONS

Follow the instructions below which are appropriate for
the wire feeder that will be used.

LF-72 to CV-305

a) Turn the CV-305 Power switch to the "OFF" posi-

tion.

b) Connect the LF-72 control cable to the wire feed-

er receptacle on the CV-305.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

LN-742 to CV-305

a) Turn the CV-305 Power switch to the "OFF" posi-

tion.

b) Connect the LN-742 control cable to the wire feed-

er receptacle on the CV-305.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

Connection of Remote Control (K857)

NOTE: The K864 Remote Control Adapter is required

to install the K857.

Plug the K864 Remote Control Adapter into the power
source's 14-pin receptacle. 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 cable
from damage and abuse.

OUTPUT CONNECTIONS

LN-7 to CV-305

a) Turn the CV-305 Power switch to the "OFF" posi-

tion.

b) Connect the LN-7 control cable to the wire feeder

receptacle on the CV-305.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

LN-25 to CV-305

a) Turn the CV-305 Power switch to the "OFF" posi-

tion.

b) Plug a K484 jumper plug into the CV-305 wire

feeder receptacle.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

WARNING

Output cables must have Magnum Twist-Mate™ plugs
for connection to the CV-305. Order K852-95 for con­necting 2/0-3/0 (70-95 mm2) cables. Refer to S18737
for instructions on installing these plugs.

Use the shortest possible cable lengths. See Table A.1
for recommended cable sizes based on length.

Connect the positive output lead to the terminal
marked "+". The negative output lead can be hooked
to either the low inductance terminal (marked "

") or the high inductance terminal (marked

" ").

TABLE A.1

Cable Sizes for Combined Lengths of Copper

Electrode and Work Cable

Machine Size

315 A 100% 2/0 (70mm2) 3/0 (95mm

Lengths up to

150 ft 150 to 200 ft

2

)

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

------------------------------------------------------------------------

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IDEALARC® CV-305

A-5 A-5

INSTALLATION

PARALLELING

The CV-305 is not designed to be paralleled with
another C-305 or with any other power source.

CONNECTION OF AUXILIARY EQUIPMENT
TO THE WIRE FEEDER RECEPTACLE

Occasionally, it may be necessary to make connection
to the circuits present in the 14-pin wire feeder recep­tacle. These circuits, such as the auxiliary voltage,
contactor, and remote control circuits, may be
accessed with a K867 Universal Adapter. This adapter
plugs into the receptacle and provides the user with
short wire leads for connections. Refer to the instruc­tions provided with the K867, as well as the wiring dia­gram for the CV-305 power source, for details on mak­ing those connections. For your convenience, wire
feeder connection details are shown in the DIAGRAM
section.

NOTE: If you intend to use a standard Lincoln wire

feeder, order the appropriate input cable for
the specific feeder. It will make all of the con­trol and power connections between the CV­305 and the wire feeder WITHOUT the need
for a K867 Universal Adapter.

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IDEALARC® CV-305

A-6 A-6

NOTES

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IDEALARC® CV-305

B-1 B-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Graphic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Casefront Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Starting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Local/Remote Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Aux. Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

TABLE OF CONTENTS - OPERATION SECTION

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

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IDEALARC® CV-305

B-2 B-2

OPERATION

SAFETY PRECAUTIONS

Read this entire section of operating instructions
before operating the machine.

WARNING

ELECTRIC SHOCK can kill.

• Unless using cold feed feature, when
feeding with gun trigger, the electrode and
drive mechanism are always electrically
energized and could remain energized

several seconds after the welding ceases.

• Do not touch electrically live parts or electrodes with
your skin or wet clothing.

• 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.

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held

combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional guidelines detailed in the beginning
of this manual.

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IDEALARC® CV-305

B-3 B-3

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

INPUT POWER

ON

OFF

HIGH TEMPERATURE

MACHINE STATUS

CIRCUIT BREAKER

WIRE FEEDER

U

U

U

SMAW

GMAW

FCAW

GTAW

OPEN CIRCUIT VOLT-

0

1

2

AGE

INPUT VOLTAGE

OUTPUT VOLTAGE

POSITIVE OUTPUT

NEGATIVE OUTPUT

3 PHASE INVERTER

INPUT POWER

THREE PHASE

DIRECT CURRENT

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IDEALARC® CV-305

I

1

I

2

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

B-4 B-4

CAUTION

OPERATION

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

When using a CV-305 power source with wire feeders,
there will be a small spark if the electrode contacts the
work or ground within several seconds after releasing
the trigger.

When used with some wire feeders with the electrical
trigger interlock in the ON position, the arc might restart
if the electrode touches the work or ground during
these several seconds.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The CV-305 is a constant voltage DC power source
designed for the GMAW process with limited FCAW
capability as well. It features an industrial rating of 315
amps, 32.6 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.

• 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.

DESIGN FEATURES

•"Clean" appearance and simple controls -- easy to

operate.

• Electronic and thermostatic protection from over­loads.

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

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

RECOMMENDED PROCESSES AND
EQUIPMENT

The CV-305 is capable of solid wire welding within the
rated output capacity of the machine. It is also capa­ble of welding with flux-cored wires.

The CV-305 is recommended for use with the LF-72,
LN-7, LN-742 and LN-25 wire feeder models.

OPERATIONAL FEATURES AND
CONTROLS

• 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.

• Power on/off switch.

• Compact size, requires only 19" x 26"(482mm x
660mm) footprint.

• Modular construction for easy servicing.

• Recessed panels protect output studs and controls.
Large safety margins and protective circuits protect
rectifiers from transient voltages and high currents.

POWER SOURCE OPERATION

Be sure the CV-305 is properly installed, and that all
accessories are properly hooked up before attempting
operation.

DUTY CYCLE

315 Amps, 32.6 Volts at 100%

*Duty Cycle is based on operation for a 10 minute period.

*

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

• Circuit breaker protected.

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IDEALARC® CV-305

B-5 B-5

OPERATION

CONTROLS AND OUTPUT SETTINGS

All operator controls and adjustments are located on the case front of the CV-305. Refer to Figure B.1.

FIGURE B.1 - CONTROL AND OUTPUT PANEL

5

4

8

7

6

10

11

1. POWER SWITCH

A two-position toggle switch.Controls the input
power to the CV-305.

2. VOLTAGE ADJUST

3

1

2

9

13

12

NOTE: Due to voltage drops in the welding cables

and at 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.

Controls the CV-305 output voltage.

3. THERMAL PROTECTION INDICATION LIGHT

Indicates that the protection thermostat has
activated. The digital meter will display "E10" when
this occurs. When the light turns off, the machine
will be capable of supplying welding output power
again.

NOTE: Leaving the power switch in the "ON" posi-

tion will result in the most rapid cooling.

4. VOLTS/AMPS SWITCH

Selects either output current or arc voltage to be
displayed on the digital meter.

5. DIGITAL VOLTMETER/AMMETER

Displays the CV-305 output current, or the arc volt­age.

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-305 will work normally.
However, any equipment powered by the 42 volt
circuit will not work.

7. 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-305 will work normally.
However, any equipment powered by the 115 volt
circuit will not work.

8. LOCAL/REMOTE SWITCH

Determines whether the welding voltage is con­trolled at the CV-305, or controlled remotely by a
remote output control (such as a K857).

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IDEALARC® CV-305

B-6 B-6

OPERATION

9. WIRE FEEDER VOLTMETER SWITCH

This switch selects the polarity of the WORK sens­ing lead (#21) to the wire feeder. 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 "-".

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.

10. POSITIVE OUTPUT CONNECTION.

The Positive (+) Output Connector is a Magnum
Twist-Mate™, receptacle. Insert a mating Twist­Mate™ plug, and twist clockwise to secure.

11. LOW INDUCTANCE NEGATIVE CONNECTION.

The Low InductanceOutput con­nector is a Magnum Twist-Mate™,
receptacle. Insert a mating Twist­Mate™ plug, and twist clockwise to
secure.

12. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION.

The High Inductance Output connec­tor is a Magnum Twist-Mate™, recep­tacle. Insert a mating Twist-Mate™
plug, and twist clockwise to secure.

The high inductance connection is more suitable
for short arc welding heavier weldments or when
using 75% Argon/25% CO
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.

Note: For GMAW processes, and most FCAW

processes, the positive output connection goes
to the wire feeder. One of the negative output
connections goes directly to the work.

13. WIRE FEEDER RECEPTACLE

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

2 shielding gas. This

The low inductance connection is typically used
for short arc welding of mild steel, particularly on
thin materials or when using CO2shielding gas.

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IDEALARC® CV-305

B-7 B-7

OPERATION

STARTING THE MACHINE

The power switch at the extreme right side of the con­trol panel energizes the CV-305.

ADJUSTING THE OUTPUT VOLTAGE
USING THE DIGITAL METER

The digital meters in the CV-305 incorporate a voltage preset
function. This allows the operator to set the desired welding
voltage before striking an arc. The digital meters 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.)

When an arc is struck, the digital meter displays the actual
welding voltage, as measured at the CV-305 output termi­nals.

NOTE: The arc voltage at the electrode may be as much as

two volts different from the CV-305 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-305 for a slightly higher weld­ing voltage than your procedure calls for.

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

LOCAL/REMOTE SWITCH OPERATION

If voltage control is desired at the CV-305, the Local/Remote
switch must be in the "Local" position. The Voltage Adjust on
the front panel can be used to adjust the CV-305 output.
(The remote control, even if connected, will have no effect if
the switch is in the "Local" position).

AUXILIARY POWER

42 volt AC auxiliary power, as required for some wire
feeders, is available through the wire feeder recepta­cle. A 10 amp circuit breaker protects the 42 volt cir­cuit from overloads.

CV-305 machines can also supply 115 volt AC auxiliary
power through the wire feeder receptacle. A 5 amp cir­cuit breaker protects the 115 volt circuit from over­loads.

NOTE: Do not use circuits 2 or 4 for control of auxiliary

loads. (The 2-4 circuit is isolated from the 31­32 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-305 auxiliary power for that equip­ment.

___________________________________________

OVERLOAD PROTECTION

This welder has thermostatic protection from excessive
duty cycles, overloads, loss of cooling, and high ambi­ent temperatures. When the welder is subjected to an
overload or loss of cooling, a thermostat will open. This
condition will be indicated by the illumination of the yel­low Thermostatic Protection Light on the case front
(see Figure B.1).The fan will continue to run to cool
the power source. No welding is possible until the
machine is allowed to cool and the Thermostatic
Protection Light goes out.

To use a wirefeeder that has remote control capability or a
remote control, such as the K857 (see INSTALLATION sec-
tion), place the Local/Remote switch (see Figure B.1) in the
"Remote" position. The remote control now controls the out­put voltage, in the manner described above. This control
may be adjusted while welding to change the CV-305 output.

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IDEALARC® CV-305

B-8 B-8

NOTES

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IDEALARC® CV-305

C-1 C-1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

Factory Installed Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Field Installed Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Compatible Lincoln Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

TABLE OF CONTENTS - ACCESSORIES SECTION

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IDEALARC® CV-305

C-2 C-2

ACCESSORIES

FACTORY INSTALLED
OPTIONS/ACCESSORIES

There are no factory installed options/accessories on
the CV-305.

FIELD INSTALLED OPTIONS

REMOTE VOLTAGE CONTROL (K857)

The K857 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-305 requires a K864 Remote
Control Adapter. Refer to the instructions provided with
the K857 for hookup to the CV-305. When properly
connected, and with the CV-305 Local-Remote Switch
in the "Remote" position, the K857 functions the same
as the CV-305 Voltage Adjust control, enabling mini­mum to maximum output voltage adjustment of the CV-

305.

(1)

Also available is a K857-1 w/6 Pin MS-Type
(Amphenol) Plug and 100 feet (30.4m) cable.

(1)

COMPATIBLE LINCOLN EQUIPMENT

The CV-305 is intended for use with the LF-72, LN-7,
LN-742, and LN-25 wire feed units. Use the Cables /
Kits listed below to make connection easily:

LF-72 Requires K1797-XX

Control Cable(Included with
Wire Feeder is a K1797-10)

LN-7 / LN-7GMA Requires K1818-10 Input Cable

LN-25

LN-25 w/K444-1 Requires K864 Remote Control
Remote Voltage Adapter and K484 Jumper Plug
Control Kit Kit

LN-25 w/K444-2 No Additional kits required

LN-742 / LN-742H Requires K1819-10 Input Cable

Requires K484 Jumper Plug Kit

TWO-CYLINDER UNDERCARRIAGE (K874)

Platform type undercarriage that can accommodate
either one or two gas bottles, or one gas bottle and a
Magnum water cooler. The CV-305 lifting eye is not
functional when the K874 undercarriage is installed.

UNIVERSAL ADAPTER (K867)

Provides a means of connecting auxiliary equipment to
the wire feeder receptacle on the CV-305 power
source. 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. Not required
when using a standard Lincoln wire feeder input cable
with a Lincoln wire feeder.

TWIST-MATE CABLE PLUG (MALE)

• For 1/0-2/0 (50-70 mm2) Cable (K852-70)

2

• For 2/0-3/0 (70-95 mm

) Cable (K852-95)

TWIST-MATE CABLE RECEPTACLE
(FEMALE)

• For 1/0-2/0 (50-70 mm2) Cable (K1759-70)

2

• For 2/0-3/0 (70-95 mm

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) Cable (K1759-95)

IDEALARC® CV-305

D-1 D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Machine & Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

TABLE OF CONTENTS - MAINTENANCE SECTION

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IDEALARC® CV-305

D-2 D-2

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this maintenance.

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

• Do not touch electrically hot
parts.

GENERAL MAINTENANCE

1. The fan motor has sealed bearings which require
no service.

2. In extremely dusty locations, dirt may clog the air
channels causing the welder to run hot with prema­ture tripping of thermal protection. Blow out the
welder with low pressure air at regular intervals to
eliminate excessive dirt and dust build-up on inter­nal parts.

MACHINE AND CIRCUIT PROTECTION

The CV-305 Control PC Board has built-in diagnostic
routines to alert the operator when trouble exists.
When a trouble condition occurs, the CV-305 meter will
display an error code, in the form "EXX", where "XX"
refers to a specific error. See TROUBLESHOOTING
section for an explanation of the error codes.

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 the
machine cools, at which time it will close and the out­put will again be available.

The CV-305 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-305
output. The short circuit protection circuit can be reset
by turning the CV-305 Power switch OFF for at least 10
seconds. Remove the short before turning the Power
switch ON again.

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IDEALARC® CV-305

D-3 D-3

44

22

66

11

55

22

33

MAINTENANCE

FIGURE D.1. - Major Component Location

1. Casefront

2. Cover Assembly

3. Center & Base Assembly

4. Capacitor Bank Assembly

5. Case Back Assembly

6. Fan, Terminal Board & Choke Assembly

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IDEALARC® CV-305

D-4 D-4

NOTES

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IDEALARC® CV-305

E-1 E-1

INPUT

LINE

SWITCH

MAIN

TRANSFORMER

RECONNECT

PANEL

FAN

MOTOR

OUTPUT

RECTIFIER

+

SHUNT

CHOKE

OUTPUT
TERMINALS

CONTROL BOARD

F
E
E
D
B
A
C
K

G
A
T
E
S

METER

OUTPUT

CONTROL

14 PIN

AMPHENOL

TRIGGER AND REMOTE

12VAC

12VAC

4
2
V
A
C

-

CAPACITORS

+

F
E
E
D
B
A
C
K

-

-

115VAC

POWER FACTOR

ENHANCEMENT

CHOKE

TABLE OF CONTENTS-THEORY OF OPERATION SECTION

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1

Input Line Voltage, Line Switch & Main Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2

Output Rectification, Filtering, Control & Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3

SCR Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5

FIGURE E.1 — BLOCK LOGIC DIAGRAM.

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IDEALARC® CV-305

E-2 E-2

INPUT

L

INE

S

WITCH

M

AIN

T

RANSFORMER

RECONNECT

PANEL

FAN

MOTOR

OUTPUT

RECTIFIER

+

S

HUNT

C

HOKE

O

UTPUT

T

ERMINALS

C

ONTROL BOARD

F
E
E
D
B
A
C
K

G
A
T
E
S

M

ETER

O

UTPUT

C

ONTROL

1

4 PIN

A

MPHENOL

TRIGGER AND REMOTE

12VAC

1

2VAC

4
2
V
A
C

-

CAPACITORS

+

F
E
E
D
B
A
C
K

-

-

115VAC

POWER FACTOR

ENHANCEMENT

C

HOKE

THEORY OF OPERATION

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 305 through an input line switch located on the
front of the machine. A reconnect 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 equip­ment. 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.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

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IDEALARC® CV-305

E-3 E-3

INPUT

L

INE

S

WITCH

M

AIN

T

RANSFORMER

RECONNECT

P

ANEL

FAN

MOTOR

OUTPUT

RECTIFIER

+

SHUNT

C

HOKE

O

UTPUT

T

ERMINALS

C

ONTROL BOARD

F
E
E
D
B
A
C
K

G
A
T
E
S

M

ETER

O

UTPUT

C

ONTROL

1

4 PIN

A

MPHENOL

TRIGGER AND REMOTE

1

2VAC

1

2VAC

4
2
V
A
C

-

C

APACITORS

+

F
E
E
D
B
A
C
K

-

-

115VAC

POWER FACTOR

E

NHANCEMENT

C

HOKE

THEORY OF OPERATION

FIGURE E.3 — Output Rectification, Filtering, Control Feedback, & Power Factor Enhancement

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 (see SCR Operation). 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.

The capacitors and the output choke provide the filter­ing for the controlled DC output of the CV 305 machine.
The choke is tapped for supplying either a soft (high
inductance) or a more harsh (low inductance) welding
arc.

NOTE: Unshaded areas of Block Logic

Diagram are the subject of discussion

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IDEALARC® CV-305

A power factor correcting choke added between the
Output Rectifier ant the Capacitor Bank enables the
CV 305 to provide 20% greater efficiency as compared
to the CV 300.

E-4 E-4

A thermostat protects the CV-305 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-305 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.

THEORY OF OPERATION

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IDEALARC® CV-305

E-5 E-5

INPUT

O

UTPUT

CATHODE

ANODE

GATE

N

OTE: AS THE GATE
PULSE IS APPLIED
L

ATER IN THE CYCLE
THE SCR OUTPUT
I

S DECREASED.

THEORY OF OPERATION

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.

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-305

E-6 E-6

NOTES

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IDEALARC® CV-305

F-1 F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR

How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Diagnostic Routines & Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-11

Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Main Transformer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Static Output SCR Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17

Choke Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21

PFC (LI) Coil Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23

Active SCR Rectifier Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25

Scope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Removal & Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35

Control PC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35

Capacitor Bank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37

Output Rectifier Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41

Mounting of Stud Type Diodes to Aluminum Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43

SCR’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45

Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51

Center Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53

Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-55

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IDEALARC® CV-305

F-2 F-2

TROUBLESHOOTING & REPAIR

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, wire feeding 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
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.

to eliminate

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 1-888-935-3877.

-----------------------------------------------------------------------------------------------------------------------------------

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IDEALARC® CV-305

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

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 elec trically 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 procedures:

PC board can be damaged by static electricity.

- Remov e y our bod y ’s s t atic
charge before opening the static­shielding bag. Wear an anti-static
wri s t strap. F o r safety, u s e a 1
Meg ohm resistive cord connected
to a g round e d pa rt of th e

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

equipment frame.

- If you don’t have a wrist strap,
touch an un -painte d, grounded,
part of the equipment frame. Keep
touc h ing the fr ame to p reve n t
stat i c buil d -up. B e s ure n o t to
touch any electrically live parts at
the same time.

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

- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.

- If you return a PC 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. Tes t the machine to determ ine if the failure

symp t om h as bee n c o rrect e d b y t he
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 component s can reac h the ir op erating
temperature.

5. Re m ove th e repla c emen t PC b oard an d

subs t itute i t w ith the o r igina l P C b oard to
recreate the original problem.

a. If the original problem does not reappear by

substituting the original board, then the PC
board was not the problem. Continue to look
for bad conne ctions in the con trol w iring
harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC
boar d wa s th e pr o blem. Rei n stal l th e
replacement PC board and test the machine.

6. Al w ays i n dicat e th a t th i s pro c edure w as

foll o wed w h en wa r ranty re port s are t o 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.

- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.

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IDEALARC® CV-305

F-4 F-4

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

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

MISADJUSTMENT(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. 1-888-935-3877

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. Swap any two of the three phase
input. If output returns, the Line
Switch is faulty.

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

5. The control board may be faulty.
Replace.

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 1-888-935-3877.

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IDEALARC® CV-305

F-5 F-5

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

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

POSSIBLE AREAS OF

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

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

6. The control board may be
faulty. Replace.

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 1-888-935-3877.

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IDEALARC® CV-305

F-6 F-6

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

Machine has high output and no control.

Machine does not have maximum output.

POSSIBLE AREAS OF

MISADJUSTMENT(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.

RECOMMENDED

COURSE OF ACTION

1. Perform the Output Rectifier
Bridge Test.

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

3. The control board may be
faulty. Replace.

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

2. Make sure all three phases are
present.

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

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

3. The control board may be faulty.
Replace.

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 1-888-935-3877.

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IDEALARC® CV-305

F-7 F-7

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The meter does not light. The machine operates properly.

POSSIBLE AREAS OF

MISADJUSTMENT(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-305
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.

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 1-888-935-3877.

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IDEALARC® CV-305

F-8 F-8

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The machine will NOT shut off.

The output voltage cannot be pre­set.

POSSIBLE AREAS OF

MISADJUSTMENT(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.

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.

2. If an error message is displayed

see Explanation of Error
Messages.

3. The control board may be faulty.
Replace.

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 1-888-935-3877.

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IDEALARC® CV-305

F-9 F-9

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The output voltage cannot be pre­set.

The weld output terminals are always electrically “hot”.

POSSIBLE AREAS OF

MISADJUSTMENT(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 CV305.
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 Output Rectifier
Bridge Test.

3. The snubber board may be
faulty. Replace.

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 1-888-935-3877.

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IDEALARC® CV-305

F-10 F-10

Observe Safety Guidelines detailed in the beginning of this manual.

TROUBLESHOOTING & REPAIR

PROBLEMS

(SYMPTOMS)

The welding arc is variable and sluggish.

The arc striking is poor.

POSSIBLE AREAS OF

MISADJUSTMENT(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.

RECOMMENDED

COURSE OF ACTION

1. Perform the Output Rectifier
Bridge Test.

2. The control board may be
faulty. Replace.

3. Check the Shunt Feedback.

1. The control board may be faulty.
Replace.

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

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 1-888-935-3877.

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IDEALARC® CV-305

F-11 F-11

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.

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.
Insure fan operation.

Perform Main Transformer Test to
verify PC Board input voltages.
Control Board may be faulty.

1. Check wiring between Voltage
Adjust and the Control PC Board.

2. Remote Control not functioning cor­rectly.

E40

E50

E60

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).

Input line voltage too low.

Input line voltage too high.

Overload condition.

2. See Troubleshooting Guide
(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.

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 1-888-935-3877.

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IDEALARC® CV-305

F-12 F-12

NOTES

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IDEALARC® CV-305

F-13 F-13

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

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-305 wiring diagrams (See Electrical Diagrams Section of this manual)

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IDEALARC® CV-305

F-14 F-14

CIRCUIT BREAKER

CB2 (LEAD #33)

FRONT PANEL

14 PIN AMPHENOL

CONNECTOR (PIN J)

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST PROCEDURE (CONTINUED)

TEST PROCEDURE

WARNING

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

____________________________________

NOTE: Secondary voltages will vary proportionally 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 voltage is being

applied to the main transformer, continue test.

b. If the incorrect three-phase voltage is not being

applied to the main transformer, correct before
proceeding with test.

4. Locate plug J3 on the Control PC Board.

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-305 wiring diagram.

b. If voltage is present, continue test.

FIGURE F.1 - Main Transformer Test Points

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

9. Locate lead # 33 connected to circuit breaker CB2

a. Insert the meter probes carefully into the back

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

and pin "J" (lead #31) on the 14 pin amphenol con­nector located on the Case Front. See Figure F.1.

FROM LEAD

#200
#202

TO LEAD

#201
#203

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IDEALARC® CV-305

F-15 F-15

FRONT PANEL

14 PIN AMPHENOL

C

ONNECTOR (PIN I)

CB1

C

B2

LEAD #222

LEAD #221

LEAD #223

MAIN TRANSFORMER

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER TEST PROCEDURE (CONTINUED)

11. Locate lead #42A connected to circuit breaker CB1
and pin "I" on the 14 pin amphenol connector on
the Case Front. See Figure F.2.

FIGURE F.2 - Main Transformer Test Points.

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

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

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12. Test for 42 VAC between lead #42A at the circuit
breaker 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.

b. If voltage is present, continue test.

IDEALARC® CV-305

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.

F-16 F-16

NOTES

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IDEALARC® CV-305

F-17 F-17

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

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-305 Wiring Diagrams (See Electrical Diagrams Section of this Manual)
1/2" Wrench
7/16" Wrench

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IDEALARC® CV-305

F-18 F-18

CONTROL

BOARD

METER
BOARD

D1

D4

D2

Capacitor

Bank

D5

Copper

Strap

D3

Positive

Heat Sink

Power Factor

Choke Lead

*

*

*

*

The Bus Bar where the D1, D2 and D3 pigtails are normally connected is not shown for clarity.

Positive lead

to Shunt

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE (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.

See Figure F.4.

PLUG

J5
J1
J3

3. Locate resistor R1 (below the fan) and remove

lead #224A. See the Wiring Diagram.

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

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

LOCATION

Snubber board

Control board

Control Board

FIGURE F.4 - PC BOARD LOCATION

FIGURE F.5 - RECTIFIER/CAPACITOR ASSSEMBLY

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IDEALARC® CV-305

F-19 F-19

ANODE

CATHODE

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE (CONTINUED)

FIGURE F.6 - SCR TEST POINTS

6. Disconnect the D4 diode pigtail from the positive
strap. See Figure F.5.

7. Remove the red insulating paint from the heat sink
test points. See Figure F.6.

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.

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IDEALARC® CV-305

b. Reverse the meter leads and measure the

resistance from the cathode to anode of
SCR1.

c. If a low resistance is measured for either test a

or b, SCR1 is faulty. Replace the SCR assem­bly.

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

F-20 F-20

D1

D4

D2

Capacitor

Bank

D5

Copper

Strap

D3

Positive

Heat Sink

Power Factor

Choke Lead

*

*

*

*

The Bus Bar where the D1, D2 and D3 pigtails are normally connected is not shown for clarity.

Positive lead

to Shunt

TROUBLESHOOTING & REPAIR

STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE (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.7.

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.7.

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.

FIGURE F.7 - RECTIFIER/CAPACITOR ASSEMBLY

11. Test Diodes D2, D3, D4 & D5 for proper operation
using the same procedure described in Step 10.

NOTE: Diodes D1, D2 & D3 do not need to be discon-

nected for this test.

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

13. If these tests did not identify the problem or to fur­ther test the SCR’s, go to the Active SCR Test.

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IDEALARC® CV-305

F-21 F-21

TROUBLESHOOTING & REPAIR

CHOKE TEST PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The weld choke is located in front of the lift bale on the top of the transformer. This test
will help determine if the Choke is shorted to ground or is open.

MATERIALS NEEDED

Digital volt/ohmmeter

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IDEALARC® CV-305

CHOKE

F-22 F-22

TROUBLESHOOTING & REPAIR

CHOKE TEST PROCEDURE (CONTINUED)

FIGURE F.8 - CHOKE

PROCEDURE

1. Using a digital ohmmeter, make sure that the
choke windings are not grounded to the lamina­tion (> 1megohm).

No windings or terminal connections should look
burned or over-heated. Welding may cause choke
to buzz slightly.

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IDEALARC® CV-305

F-23 F-23

TROUBLESHOOTING & REPAIR

P.F.C. (LI) COIL TEST PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The P.F.C. Coil is located in down toward the left rear on the base. This test will help deter­mine if the Coil is shorted to ground or is open.

MATERIALS NEEDED

Digital volt/ohmmeter

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IDEALARC® CV-305

F-24 F-24

CHOKE

TROUBLESHOOTING & REPAIR

P.F.C. (LI) COIL TEST PROCEDURE (CONTINUED)

FIGURE F.9 - CHOKE

PROCEDURE

1. Using a digital ohmmeter, make sure that the
choke windings are not grounded to the lamina­tion (> 1megohm).

No windings or terminal connections should look
burned or over-heated. Welding may cause choke
to buzz slightly.

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IDEALARC® CV-305

F-25 F-25

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

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-305

F-26 F-26

CONTROL

BOARD

METER
BOARD

D1

D4

D2

Capacitor

Bank

D5

Copper

Strap

D3

Positive

Heat Sink

Power Factor

Choke Lead

*

*

*

*

The Bus Bar where the D1, D2 and D3 pigtails are normally connected is not shown for clarity.

Positive lead

to Shunt

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE (CONTINUED)

TEST PROCEDURE

1. Disconnect main AC input power to the machine.

2. Locate and remove the following plug. See Figure
F.10.

PLUG #

J5
J1
J3

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

4. Disconnect the strap from the positive heat sink to
the capacitor bank using a 1/2" wrench. See
Figure F.11.

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

LOCATION

Snubber board

Control board
Control Board

FIGURE F.10 -. PC BOARD LOCATION

6. Disconnect the D4 diode pigtail from the negative
strap.

FIGURE F.11 - RECTIFIER /CAPACITOR ASSEMBLY

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IDEALARC® CV-305

F-27 F-27

ANODE

CATHODE

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE (CONTINUED)

7. Remove the red insulating paint from the heat sink
test points. See Figure F.12.

NOTE: DO NOT DISASSEMBLE THE SCR RECTIFI-

ER HEAT SINK ASSEMBLY.

8. Construct the circuit shown in Figure F.13. One 6­volt 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 battery. 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.13.

a. Connect Tester lead (A) to the anode.

b. Connect Tester lead (C) to the cathode.

c. Connect Tester lead (G) to the gate at the

Control Board connector J1).See the Wiring
Diagram.

FIGURE F.12

FIGURE F.13 - SCR TESTER

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IDEALARC® CV-305

F-28 F-28

TROUBLESHOOTING & REPAIR

ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE (CONTINUED)

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.

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.

b. If the voltage is higher than zero, the SCR is

shorted.

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. Reconnect all disconnected leads and Molex Plugs.

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IDEALARC® CV-305

F-29 F-29

5ms

20V

0 Volts

CH1

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

NO LOAD - OUTPUT CONTROL AT MAXIMUM

SCOPE SETTINGS

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.

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

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

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

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

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IDEALARC® CV-305

F-30 F-30

5ms

20V

0 Volts

CH1

TROUBLESHOOTING & REPAIR

TYPICAL DC WELD OUTPUT - MACHINE LOADED

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.

SCOPE SETTINGS

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

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

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

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

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IDEALARC® CV-305

F-31 F-31

5ms

20V

0 Volts

CH1

TROUBLESHOOTING & REPAIR

ABNORMAL OUTPUT WELD VOLTAGE WAVEFORM -

MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING

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.

SCOPE SETTINGS

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

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

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

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

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IDEALARC® CV-305

F-32 F-32

5ms

20V

0 Volts

CH1

TROUBLESHOOTING & REPAIR

ABNORMAL OUTPUT WELD VOLTAGE WAVEFORM - MACHINE LOADED

CAPACITOR BANK NOT FUNCTIONING

MACHINE LOADED TO 300 AMPS AT 15 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.

SCOPE SETTINGS

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

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

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

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

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IDEALARC® CV-305

F-33 F-33

5ms

20V

0 Volts

CH1

TROUBLESHOOTING & REPAIR

ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM

NO LOAD - CAPACITOR BANK NOT FUNCTIONING

SCOPE SETTINGS

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.

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

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

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

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

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IDEALARC® CV-305

F-34 F-34

2ms

1V

0 Volts

CH1

TROUBLESHOOTING & REPAIR

TYPICAL SCR GATE VOLTAGE WAVEFORM

SCOPE SETTINGS

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.

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

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

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

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

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IDEALARC® CV-305

F-35 F-35

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

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-305

F-36 F-36

TROUBLESHOOTING & REPAIR

CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

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.

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IDEALARC® CV-305

F-37 F-37

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

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" Wrench
7/16" Wrench
Wiring Diagram
Digital Voltmeter

NOTE: If any of the capacitors fail, all four must be replaced.

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IDEALARC® CV-305

F-38 F-38

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

PROCEDURE

1. Disconnect main AC input power to the machine.

2. Test that the capacitors are discharged using a
D.C. voltmeter. Polarity must be observed.

3. Disconnect the components from the capacitor
bank assembly: See Table F.1. See Figure F. 14.

NOTE: Pay particular attention to the hardware place-

ment for reassembly.

4. Remove the two screws holding the capacitor
mounting strap to the lift bail assembly using a
5/16" Nutdriver. Note placement of insulation for
reassembly.

5. Carefully remove the capacitor bank assembly.

PART TO REMOVE

Positive Capacitor Jumper Strap

Positive Capacitor Output Lead

Negative Capacitor Output Lead to

P.F.C. Choke

TABLE F.1.

LOCATION

Positive Capacitor Buss

Positive Capacitor Buss

Negative Capacitor Left Side

TYPE WRENCH

1/2" Wrench

1/2" Wrench

1/2" Wrench

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IDEALARC® CV-305

F-39 F-39

D1

D4

D2

Capacitor

Bank

D5

Copper

Strap

D3

Positive

Heat Sink

Power Factor

Choke Lead

*

*

*

*

The Bus Bar where the D1, D2 and D3 pigtails are normally connected is not shown for clarity.

Positive lead

to Shunt

TROUBLESHOOTING & REPAIR

CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

FIGURE F.14 - CAPACITOR BANK REMOVAL

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IDEALARC® CV-305

F-40 F-40

NOTES

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IDEALARC® CV-305

F-41 F-41

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL & REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

MATERIALS NEEDED

5/16" Nutdriver
3/8" Nutdriver
1/2" Wrench
7/16" Wrench
Wiring diagram

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IDEALARC® CV-305

F-42 F-42

Insulators

Heat Sink

Mounting

Bracket

TROUBLESHOOTING & REPAIR

OUTPUT RECTIFIER BRIDGE REMOVAL & REPLACEMENT (CONTINUED)

PROCEDURE

1. Disconnect main AC input power to the machine.

2. Remove the Case Roof and Case Sides.

3. Test that the capacitors are discharged using a
D.C. voltmeter.

a. Polarity must be observed.

4. Remove the Capacitor Bank Assembly. See the

Capacitor Bank Replacement Procedure.

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

a. Disconnect leads #221, #222, and #223.

b. Note placement of leads and hardware 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.

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

a. Note the placement and arrangement of the

insulating materials on the mounting screws
for re-assembly. See Figure F.15.

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.

NOTE: If further disassembly is required, see SCR

Removal and Replacement Procedure and
Diode Mounting Instruction.

FIGURE F.15 - RECTIFIER INSULATION

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IDEALARC® CV-305

F-43 F-43

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS

PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

MATERIALS NEEDED

1/2" Open Wrench
Lincoln E1868 (Dow Corning 340) Heat Sink Compound
"Slip" Type Torque Wrench

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IDEALARC® CV-305

F-44 F-44

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS

PROCEDURE (CONTINUED)

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.

a. Do not apply compound to diode stud or

mounting threads.

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

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-305

F-45 F-45

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

MATERIALS NEEDED

NO.000 Fine Steel Wool
Penetrox A-13 (Lincoln E2529) or Penetrox A
7/16” Wrench
Allen Head Type Wrenches.

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IDEALARC® CV-305

F-46 F-46

OUTER METAL

RING

ANODE

GATE

CATHODE

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

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 F.22.

Figure F.16 - SCR

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 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.

a. Care must be used to prevent foreign mate-

rial contamination of the SCR to heat sink
junction.

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.

2. Remove the old SCR.

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 emboss/indent 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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IDEALARC® CV-305

F-47 F-47

SPRING CURVATURE

EXAGGERATED

1/2"

HOUSING

HEAT SINK

1/4-28 OR 1/4-20

CAP SCREW

SLEEVING

S.C.R.

PLAIN WASHER

LEAF

SPRING

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

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.

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.17. 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.18.

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.18. Heat sinks may not be
exactly as pictured.)

Figure F.18 - Clamp Assembly.

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Figure F.17 - 1/2" Wide Leaf Spring

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5. Re-inspect the SCR for proper seating.

IDEALARC® CV-305

F-48 F-48

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

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.

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.

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 1/4 turn.
STOP.

6. Assembly now has the proper clamping force.

7. Perform the Active SCR Test.

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IDEALARC® CV-305

F-49 F-49

STEEL PRESSURE PAD

5/8"

HOUSING

HOUSING

HEAT SINK

1/4-28 OR 1/4-20

CAP SCREW

SLEEVING

S.C.R.

HEAT SINK

PLAIN WASHER

HEX NUT

LEAF

SPRING

STEEL

PRESSURE

PAD

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT PROCEDURE (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.

3. Place the steel pressure pad in the housing with
the 1/8 inch wide standoff facing up. See Figure
F.19.

Figure F.19 - Housing and Pressure Pad for 5/8"

Wide leaf spring.

Figure F.20 - Clamp Assembly.

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. Insert clamp assembly thru heat sinks. Install nuts.

tight. Be sure that the leaf spring is not cocked in
the housing. See Figure F.20. Heat sinks may not

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be exactly as pictured.

6. Re-inspect the SCR for proper seating.

Tighten clamp nuts equally on bolts until finger

IDEALARC® CV-305

F-50 F-50

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED)

PROCEDURE FOR CLAMPING 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 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.

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.

2. Tighten first cap screw 1/4 turn.

3 Tighten second 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.

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IDEALARC® CV-305

F-51 F-51

TROUBLESHOOTING & REPAIR

FAN MOTOR AND FAN REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

MATERIALS NEEDED

5/16" Nutdriver
3/8" Nutdriver
3/8" Wrench
Wire Cutters
Allen Wrench

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IDEALARC® CV-305

F-52 F-52

Diode Buss

Bar

Snubber

Board

Reconnect

Panel

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.

4. Disconnect J5 from the Snubber PC Board.

3. Label and remove the three connections to the
Negative Diode Buss that is mounted to the fan
baffle. Pay particular attention to the mounting
sequence for reassembly.

4. Remove the three screws from the bottom of the
Case Back Panel using a 5/16" nutdriver. See
Figure F.21.

5. Remove the two screws that attach the reconnect
panel to the Case Back Panel. See Figure F.21.

FIGURE F.21 - FAN MOTOR REMOVAL

6. Remove that Case Back Panel.

7. Label and cut the fan motor leads.

8. Remove the four nuts, washers, and lock washer
which attach the fan motor to the fan bracket. See
figure F.21.

9. Remove the fan motor and blade assembly care­fully.

10. Remove the fan blade from the motor shaft using
an Allen wrench.

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IDEALARC® CV-305

F-53 F-53

TROUBLESHOOTING & REPAIR

CENTER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou­bleshooting assistance before you proceed. Call 1-888-935-3877.

MATERIALS NEEDED

5/16" Nutdriver
3/8" Nutdriver
1/2" Wrench
9/16" Wrench
3/4" Socket Wrench
Wire Cutters
Wiring Diagram

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-305

F-54 F-54

DETAIL C

DETAIL B

LEADS
#204A
#204C

WIRE OF COIL

SLEEVING

LEADS

#

221
#222
#223

DETAIL A

}

ONE PER
HEATSINK
(SEE WIRING
DIAGRAM)

A

ISO VIEW FOR REFERENCE ONLY

SEE

DETAIL D

SEE
DETAIL A

SEE
DETAIL C

SEE
DETAIL B

TROUBLESHOOTING & REPAIR

CENTER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE

(CONTINUED)

ROCEDURE

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.

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.

a. The reconnect panel can be removed with the

Center 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.

a. Make certain all leads are labeled & identified.

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

a. On some codes, the 14 pin amphenol connec-

tor 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.

FIGURE F.22

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.22.

15. Lift the Center Assembly carefully from the
machine.

a. Clear or cut any leads or cable ties that ham-

per the removal of the Center Assembly.

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-305

F-55 F-55

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

Should a machine require the removal of any mechanical part that could affect the machine’s electrical character­istics, or if any electrical components are repaired or replaced, that 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

8
7

3.4
3

Maximum Idle Watts

950 watts
950 watts
950 watts
950 watts

55 VDC

10-43 VDC

112/119 VAC

39/42 VAC

AmpsOutput Control Setting

Minimum

Maximum

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-305

40-50

410

Volts

1-7 VDC

36 VDC Minimum

F-56 F-56

NOTES

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-305

G-1 G-1

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1

Wiring Diagram Codes 11177, 11178 - (L12393) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2

Wiring Diagram Code 11179 - (L12394) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3

Schematic – Control PC Board - (G4337-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4

PC Board Assembly – Control PC Board - (L12256-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5

Schematic – Meter PC Board - (M15892) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6

PC Board Assembly – Meter PC Board - (M15893-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7

Schematic – Snubber PC Board - (S19687) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8

PC Board Assembly – Snubber PC Board - (M15370-4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-9

TABLE OF CONTENTS - DIAGRAM SECTION

* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-layered

and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.

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

IDEALARC® CV-305

12

34

1 3

4

6

CONNECT

OR CAVITY NUMBERING SEQUENCE

(COM

PONENTSIDE OFP. C

. BOARD)

ELECT

RIC

AL SYMBOLS

PE

R

E1537

+

-

L1

SE

COND

ARY

THERMOSTAT

222
223
224

D4

C1

C2

C3

C4

+

+

+

+

R1

S

CR2

D2

D5

222

204A

20

4D

CONTRO

L

P.

C

.BOA

RD

221

6 PIN

4 PIN

8 PIN

1

4

8

S

NUBBER/

BYPASS

P

.C

. BOA

RD

5

224

224A

10A

CIRCU

IT

BREAKER

CB1

L1CHOKE

2

42V

12V

12V

-

20

4C

20

4D

20

4C

277

276

275

B

A

J

C
D

206

207

211

212

31
32

2
4

1

10 PIN

5

6

10

S2

M

L

N

G

F

E

H

VOLTMETE

R

CUS

TOMER

CONNEC

TIONS

WIRE

FEEDER

115 VAC

42 VAC

GROUND

WIRE

FEEDER

RECEPTA

CLE

205

WIRE FEEDER

S3

3

1

S

CR3

D3

S

CR1

D1

8
2
3
4

1

7

6

5

213A

213A

OU

TPUT

CONTRO

L

208
209
210

1
2

3
4

J7

METER
P

.C

.

BOA

RD

VOLTS / AMPS

215

5

7

3

2

2

5

3

4

1

6

6

1

5

4

7

3

8

G1

204A

G3

G2

3

1

2

4

J1

J3

J2

J4

21

N.

A.

N.

A.

J1

J4

J7

J2
J5

J3

J5

J5

223

221

G3

G2

214A

1

2

400 A. 50mV

S

HUN

T

J1

0

1

2

2 PIN

J10

224B

224B

224B

(SHOWNIN"VOLTS" POSITI

ON)

7.5OHM
220 W

214B

214B

s

s

42A

42

41
42

I

K

C1-C4

31,000 MFDEA

CH

MAI

N TRA

NSFORME

R

C

2

41A

41

s

FAN

33A

31A

32

33

CIRCU

IT

BREAKER

5A

CB2

118V

31B

31

8

6

10

9

200

203

201

s

s

59V

59V

O2 TOP

O1 TOP

O1 TOP

O3 TOP

O3 BOT.

VOLTMETER
SWIT

CH

76

77

75

77

76

277

276

S4

(SHOWN IN LOCAL PO

SITION)

LOCAL/R

EMOTESWITCH

R2

10K

CW

376

77

377

376

377

N.

A. W

IRIN

G VIEWEDFROMREAR

OF POTENTIOMETER

242

+

-

2

L2

IN

PUT SUPPLY

L

IN

ES

S1

L

IN

E

SWIT

CH

*

RE

CONN

ECT

PANEL

11

E

8

5

2

V

N.

B.

B

UW

L1 L3

0
8
/
0
2
/
2
0
0
5

3

3

C

9

6

F

12

10

1

A

4
7

D

RE

CONNECT

PANEL

231

TOS1LINESWITC

H

RE

CONNECT

PANEL

RE

CONNECT

PANEL

RE

CONNECT

PANEL

RE

CONNECT

PANEL

RE

CONNECT

PANEL

208/230/46

0 INPUT

VOLTAGES

230/460/57

5 INPUT

VOLTAGES

208V 230V 460V

230V 460V 575V

231

TOS1LINESWITC

H

231

TOS1LINESWITC

H

231

{

TOS1LINESWITC

H

231

TOS1LINESWITC

H

231

TOS1LINESWITC

H

C

5

8

2

E

A

C

3

9

6

1

7

4

FD

B

5

8

2

E

A

C

3

9

6

1

7

4

FD

B

5

8

2

E

A

C

3

9

6

1

7

4

FD

2

E

5

8

31

F

D

6

4

9

7

2

E

5

8

31

F

D

6

4

9

7

2

E

5

8

31

F

D

6

4

9

7

N.

B. TAP LEADS A, B, A

ND C

APPEARON

THE TOP PRIMARY COILS

OF 208/230/460V MA

CHINESON

LY.

W IR ING DIA G R A

M

CV-305 (60Hz)

TO A SYSTEMGROUND

PER

NATI

ON

AL ELECT

RICAL CODE.

*

{{

{

{

{

POWERFACTOR

ENHANCEMENT

C

HO

KE

172

171

173

42B

L3

L4

L2

172
173

171

204A

202

200

203

201

219

218

218

219
W

HITE

W

HITE

RED

RED

L5

L6

320VAC

320VAC

.05uf
600V

.05uf
600V

206

205

202

275

4

213B

213B

213B

G1

L12393PRIN

T

D

G-2

WIRING DIAGRAM - CV-305 - CODES 11177 & 11178 - L12393

ELECTRICAL DIAGRAMS

G-2

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

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

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

IDEALARC® CV-305

12

34

1 3

4

6

CONNECTO

R CAVITY NUMBE

RIN

G SEQUENCE

(C

OMPONENT

SIDE OF P. C. BOARD

)

ELECTRICAL SYMBOLS
PER E

153

7

L1

SECON

DARY

THE

RMOSTAT

222
223
224

D4

C1

C2

C3

C4

+

+

+

+

R1

SCR2

D2

D5

222

204

A

204D

CONTROL
P. C. BOARD

221

6PIN

4PIN

8PIN

1

4

8

SNUBBER/BYPASS

P.C. BOARD

5

224

224

A

10A

CIRCUI

T

BREAKER

CB1

L1 CHOKE

2

42V

12V

12V

204C

204D

204C

277

276

275

B

A

J

C
D

206

207

211
212

31
32

2
4

1

10PI

N

5

6

10

S2

M

L

N

G

F

E

H

V

OLT

METER

CUS

TO

MER

CONNEC

TI

ONS

115VAC

42 V

AC

GROUND

WI

RE

FEEDER

RECEPTA

CL

E

205

WIRE FEEDE

R

S3

3

1

SCR3

D3

SCR1

D1

8
2
3
4

1

7

6

5

213

A

OUTP

UT

CONTROL

208
209

1
2
3
4

J7

METER
P.C.
BOARD

VOLTS / A

MPS

215

5

7

3

2

2

5

3

4

1

6

6

1

5

4

7

3

8

3

1

2

4

J1

J3

J2

J4

21

N.A.

N.A.

J1

J

4

J

7

J2
J5

J3

J5

J5

223

221

G3

G2

G1

214

A

1

2

400

A. 5

0mV

SHU

NT

J10

1

2

2PIN

J10

224

B

224

B

224

B

(SHO

WN I

N "VOLTS" POSITION)

7.5 OHM
220

W

214

B

214

B

s

s

42A

42

41
42

I

K

C1-

C4 31,

000

MFD EACH

MAINTRANSFORMER

C

2

41A

41

CIRCUI

T

BREAKER

220

V

52A

2A

52

51

2

L2

INPUT S

UPPLY

LINES

S1
LINE
08/03/20
05

*

RECO

NNE

CT

PANEL

11

E

8

5

2

N.C.

N.B.

* TO A SYSTEM

GROUND PE

R

NATIONAL ELECTRICAL CO

DE.

V

s

FAN

33A

31A

3233

CIRCUI

T

BREAKER

5A

CB3

CB2

118

V

31B

31

N.C. TAP LEADS D, E, AND F APPEAR ON THE BOTT

OM PRIMARY COILS

OF 3

80/500

V MACHINES ONLY.

N.B. THIS PERMANENT CONNE

CTIO

N IS MADE AT THE MAIN TRANSFO

RMER

FOR 415

V, 2

00/400

V, AND 380/

500

V MACHINES ONLY.

WU

L1 L3

13

3

9

6

F

12

1

7

4

D

10

8

6

10

9

20

2

200

203

201

s

50

s

57V

61V

O2 TOP

O1 TOP

O1 TOP

O3 TOP

O3 BOT.

O2 BOT.

O1 BOT.

127

V

127

V

s

s

2

5

8

E

5

8

380/500

INPUTVOLT

AGES

415

INPUTVOLT

AGE

5

8

200/400

INPUTVOLT

AGES

31

694

7

97

64

FD

64

9

7

220/380/440

INPUTVOLT

AGES

RE

CONNECT

PANEL

220

V

RE

CONNECT

PANEL

380

V

RE

CONNECT

PANEL

440

V

RE

CONNECT

PANEL

RE

CONNECT

PANEL

RE

CONNECT

PANEL

500

V

380

V

415

V

RE

CONNECT

PANEL

RE

CONNECT

PANEL

200

V

400

V

23 1

TO S1LINESWIT

CH

23

1

TO S1LINESWIT

CH

2

3 1

TO S1LINESWIT

CH

2

3

1

TO S1LINESWIT

CH

2

3

1

TO S1LINESWIT

CH

23 1

TO S1LINESWIT

CH

23 1

TO S1LINESWIT

CH

23 1

TO S1LINESWIT

CH

5

8

2

111012

3

1

9

6

4

5

8

2

111012

3

1

9

6

4

5

8

2

111012

3

1

9

7

6

4

77

231 231

231 231

E

5

8

FD

64

9

7

5

897

64

VOLTMETER
SWITC

H

76

77

75

77

277

276

S4

(S

HOWN IN LOCAL POSITION)

LOCAL/REMOTE

SWI

TCH

R2

10K

CW

376

77

76

377

376

377

N.A. WIRING VIEWED

FROM REA

R OF POTEN

TIOMETER

242

2

NC

+

-

WIRE F

EEDER

W IR IN G DIAG R A

M

CV 400-I (EXPORT 50/60 Hz)

L1

2394

PRINT

C

POWERFACTOR

ENHANCEMENT

C

HO

KE

G1

204A

G3

G2

172

171

173

42B

L3

L4

20

2

200

203

201

204A

172

171

173

218

219

RE

D

W

HI

TE

219

218

RE

D

W

HI

TE

-

-

320VAC

L6

L2

L5

275

.05uf
600V

206

205

+

213A

320VAC

.05uf
600V

4

213B

213B

213B

210

G-3

WIRING DIAGRAM - CV-305 CODE 11179 - L12394

ELECTRICAL DIAGRAMS

G-3

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

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

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

IDEALARC® CV-305

G-4

SCHEMATIC -CONTROL PC BOARD - ALL CODES - G4337-1

ELECTRICAL DIAGRAMS

G-4

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

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

IDEALARC® CV-305

ITEM

QTY

PART NUMBER DESCRIPT ION

11

L12256-C

PC BOARD BLANK

25

S14020-5

PLASTIC EXPANSION NUT, 0.25

31

S20590-1

HEAT SINK,SLIP ON,FORTO-220

41

T15176

LED,SP ACER,0. 220 HIGH

5 0. 2 oz

E2861

RTV SEALANT

CAPACITORS = MFD / VOLTS
RESISTORS = OHMS, 1/4 WATT

NOTES:

N.A.

DO NOT COAT WITH ENCAPSULATION.

N.B.

CAUTION:

THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC

ELECTRICITY. SEE E2454 BEFORE HANDLING.

N.C.

“LED1” TO BE MOUNTED ON OPPOSITE COMPONENT SIDE WITH
ITEM 4 AS SHOWN.

N.D.

AFTER COMP

LETE ASSEMBLY AND TEST, SEAL “X2” TO BOARD

WITH ITEM 5 . COAT THE PINS AND THE ENDS OF “X2”

WITH SEALANT LEAVING NO VOIDS BETWEEN “X2” AND BOARD.

LED1

CV CONTROL

L12256-1

R58

D26

R6

2

C32

R10

C42

C1

8

D6

R71

C5

D9

D5

R4

7

R8

7

D19

R28

R43

R46

R66

Q9

C27

R3

R93

C8

D1

3

R8

2

R59

R11

D21

R37

C9

D29

R75

R90

C21

R69

R1

00

C23

R3

1

R50

J2

D18

R79

R96

D38

R9

J4

R72

R23

R55

D2

R52

D4

1

D24

C3

R95

R6

3

C20

D7

X3

D36

Q6

R38

C15

R7

R1

3

C16

R15

R20

DZ3

R54

C1

R91

R21

R70

J6

DZ

4

R29

C25

R9

7

R45

D3

9

DZ1

C2

8

C4

D35

D23

R19

R44

C30

C36

C1

2

C41

Q4

R2

D40

DZ

8

C22

D11

R1

Q8

D22

C13

R57

C6

Q2

R60

R6

1

C2

9

DZ2

D4

3

Q5

R1

7

R33

C1

1

R18

Q3

C19

X2

R51

R8

D20

C34

R94

R34

R30

R77

R73

Y1

C7

X1

D31

R3

6

C4

4

R35

D27

R80

D4

2

R98

R42

R68

R6

R49

R27

D17

R2

4

D30

R39

D3

D32

D37

D12

C26

D15

R53

DZ

7

J1

C37

C38

D4

C2

R9

9

R32

R8

6

DZ

5

R76

Q1

R48

C3

1

D33

R41

DZ6

R92

C40

R1

01

J10

C14

D10

C33

R8

5

D1

4

C3

9

D8

DZ9

R26

R12

D1

R6

5

R22

C10

R40

R78

D25

Q7

R16

D28

D34

J3

C35

R14

XXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXXXXXXXXX

XXXX

XXXX

TOP VIEW (COMP. SIDE) BOTTOM VIEW (OPP. COMP. SIDE)

2

4

0

0

4.

25

6.

30

5N.D.

3

1

REFERENCES

QTY

PART NUMBER DESCRIPTI ON

C1, C6, C13, C14, C15,
C18, C19, C37, C38, C39

10

S16668-11

CAPACITOR,CEMO,0.1, 50V,10%

C2

1

S13490-121

CAPACITOR,ALE L,1000,35V ,+30/ -20%

C3, C4, C12 3

S13490-42

CAPACITOR,TAEL,1.0,35V,10%

C5, C33 2

S16668-1

CAPACITOR,CEMO ,22pF, 100V,5%
C7, C8, C9, C11, C16,
C20, C21, C22, C23, C25,
C26, C27, C30, C31, C34,
C35, C36, C44

18

S16668-5

CAPACITOR,CEMO,.022,50V,20%

C10

1

T11577-38K

CAPACITOR,CD,.02, 600V, +80/-20%
C28, C29 2

S16668-10

CAPACITOR,CEMO ,4700pF, 50V,2%
C32

1

S16668-2

CAPACITOR,CEMO ,47pF, 100V,5%
C40, C41, C42 3

S16668-7

CAPACITOR,CEMO,820pF,50V,5%
D1, D2, D3, D4, D5, D6,
D7, D9, D11, D13, D14,
D15, D17, D18, D19, D20,
D21, D22, D23, D24, D25,
D26, D27, D28, D29, D30,
D31, D32, D33, D34, D35,
D36, D37, D38

34

T12199-1

DIODE,AXLDS,1A, 400V

D8, D10, D12, D39, D40,
D41, D42

7

T12705-34

DIODE,AXLDS,1A, 400V,FR, 1N4936

D43

1

T12705-64

DIODE,SCHOTTKY,AXLDS,0.2A,30V,BAT42
DZ1

1

T12702-55

ZENER DIODE,1W ,8.2V ,5% ,1N4738A
DZ2, DZ6, D Z8 3

T12702-45

ZENER DIODE,1W ,18V, 5%, 1N4746A
DZ3, DZ7, D Z9 3

T12702-26

ZENER DIODE,1W ,27V, 10%, 1N4750A
DZ4

1

T12702-52

ZENER DIODE,1W ,5.1V ,5% ,1N4733A
DZ5

1

T12702-53

ZENER DIODE,1W ,3.3V ,5% ,1N4728A

N.A .

J1

1

S18248-4

CONNECTOR,M OLEX,M INI,PCB ,4-P IN

N.A .

J2

1

S18248-8

CONNECTOR,M OLEX,M INI,PCB ,8-P IN

N.A .

J3

1

S18248-10

CONNECTOR,M OLEX,M INI,PCB ,10-P IN

N.A .

J4

1

S18248-6

CONNECTOR,M OLEX,M INI,PCB ,6-P IN

N.A .

J6

1

S18248-12

CONNECTOR,M OLEX,M INI,PCB ,12-P IN

N.A .

J10

1

S24952-2G

CONNECTOR,M OLEX,M INI,PCB ,2-P IN,GOLD

N.A ., N.C.

LED1

1

T13657-4

LED,T-1,3/4, YELLOW ,HLMP -3400
Q1, Q2, Q4, Q6, Q8, Q9 6

T12704-68

TRANSISTOR,NPN,TO226,0.5A ,40V, 2N4401

N.B. Q3, Q5, Q7 3

T12704-52

TRANSISTOR,NMF,TO226,.195A , 60V,B S170(SS )
R1

1

T10812-79

TRIMMER,ST,1/2W,100, 10%,LINEAR
R2, R3 2

S19400-2000

RESISTOR,MF, 1/4W ,200,1%
R6, R55, R95 3

S19400-1500

RESISTOR,MF, 1/4W ,150,1%
R7, R31 2

T14648-5

RESISTOR,WW,5W,3.3K,5%,SQ
R8, R30, R35, R58, R60,
R61, R62, R63, R80, R94

10

S19400-4750

RESISTOR,MF, 1/4W ,475,1%

R9, R10, R11, R98, R99,
R100

6

S19400-2211

RESISTOR,MF,1/4W,2.21K,1%

R12, R16, R20, R33, R34,
R36, R37, R45, R46, R47,
R57, R78, R79, R86

14

S19400-4751

RESISTOR,MF,1/4W,4.75K,1%

R13, R15, R17, R19, R21,
R23, R26, R50, R53, R54,
R59

11

S19400-1001

RESISTOR,MF,1/4W,1.00K,1%

R14, R18, R22, R75, R76,
R77

6

S19400-30R1

RESISTOR,MF,1/4W,30.1,1%

R24, R97 2

S19400-1004

RESISTOR,MF, 1/4W ,1.00M ,1%
R27, R29, R32, R41, R42,
R43, R49, R66, R71, R72

10

S19400-1002

RESISTOR,MF,1/4W,10.0K,1%

R28

1

S19400-1212

RESISTOR,MF,1/4W,12.1K,1%
R38

1

S19400-5622

RESISTOR,MF,1/4W,56.2K,1%
R39

1

S19400-2212

RESISTOR,MF,1/4W,22.1K,1%
R40, R73, R101 3

S19400-1003

RESISTOR,MF,1/4W,100K,1%
R44

1

S19400-1501

RESISTOR,MF,1/4W,1.50K,1%
R48

1

S19400-9090

RESISTOR,MF, 1/4W ,909,1%
R51

1

S19400-6810

RESISTOR,MF, 1/4W ,681,1%
R52, R69 2

S19400-5112

RESISTOR,MF,1/4W,51.1K,1%
R65, R82 2

S19400-1502

RESISTOR,MF,1/4W,15.0K,1%
R68

1

S19400-4322

RESISTOR,MF,1/4W,43.2K,1%
R70

1

S19400-9092

RESISTOR,MF,1/4W,90.9K,1%
R85

1

S18380-1

THERMISTOR,PTC,56 OHMS,90MA
R87

1

S19400-4321

RESISTOR,MF,1/4W,4.32K,1%
R90, R91, R92, R93 4

S19400-10R0

RESISTOR,MF,1/4W,10.0,1%
R96

1

S19400-3322

RESISTOR,MF,1/4W,33.2K,1%
X1

1

S15128-15

IC,VOLT REG,ADJ,3-T,(+),3A,350,TO220

N.B ., N.D.

X2

1

S26106-2

ROM ASSEMBLY
X3

1

S15128-16

IC,OP-AMP,QUAD,HIGH-PERF,1014
Y1

1

S16665-1

CRYSTAL,QUA RTZ,3.579545MHZ,HC-18/U

REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW

G-5

PC BOARD ASSEMBLY - CONTROL PC BOARD - L12256-1

ELECTRICAL DIAGRAMS

G-5

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

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 pro-

vided 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.

IDEALARC® CV-305

G-6

SCHEMATIC - METER PC BOARD - M15892

ELECTRICAL DIAGRAMS

G-6

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

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

IDEALARC® CV-305

MET

ER

M15893-3

Q1

X5

X4

X3

X2

X1

R28

R27

R26

R25

R24

R23

R22

R21

R20

R19

R18

R17

R16

R15

R14

R13

R12

R11

R10

R9R8R7

R6

R5R4R3

R2

R1

LED3LED2LED1

D1

C8

C7

C6

C5

C4

C3

C2

C1

D2

NOTES

N.A. DONOT

COA

TWI

TH ENCAPSULATION.

N.B. CAUTION:

THIS

DEVICE I

S SUBJECTTO DAMA

GE

B

Y STAT

IC EL

ECTRICITY.

SEE E

2454BEDORE HANDLING.

N.C. TOPSURFACE OF DIS

PLAYSTO

BE FREEOFENCAPSULATION

MA

TERIAL.ALL DIS

PLA

YS MUSTBE FROMTHE S

AME V

ENDOR.

INDUCTANCE= HENR

IES

RE

SIST

ANCE=OHMS

CAPAC

ITANCE

=MFD

/VOLTS

UN

LESS O

THERW

ISE S

PECIFIED:

0

.5

5

3.

75

4.00±.0

4

0

.2

5

2.

25

2.50±.0

4

ITEM

QTY

PART NUMBER DESCRIP TI ON

1 1

M15893-E

PC BOARD BLANK

23

S14020-5

PLASTIC EXPANSION NUT, 0.38

REFERENCES

QTY

PART NUMBER DESCRIP TI ON

C1,C2,C3,C4,C7,C8 6

S16668-5

CAPACITOR,CEMO,.022,50V,20%

C5, C6 2

S16668-8

CAPA CITOR,CEMO,330pF,100V ,5%

D1

1

T12199-1

DIODE,AXLDS,1A, 400V

D2

1

T12705-22

DIODE,A XLDS,0.15A ,75V ,1N914

J7

1

S18248-4

CONNECTOR,MOLEX,MINI,P CB, 4-P IN

LED1, LE D2, LED3 3

S17395

LED,DISPLAY,7-SEGMENT,CA,MAN6660

Q1

1

T12704-26

TRANSISTOR,ND,TO226,0.5A,30V,MPS-A13

R1

1

S19400-4750

RESISTOR,MF,1/4W,475,1%

R2

1

S19400-3321

RESISTOR,MF,1/4W,3.32K,1%
R3,R4,R5,R6,R7,R8,
R9, R10, R11, R12, R13,
R14, R15, R16, R17, R18,
R19, R20, R21, R22, R23,
R24, R25, R26

24

S19400-1000

RESISTOR,MF,1/4W,100,1%

R27, R28 2

S19400-3011

RESISTOR,MF,1/4W,3.01K,1%
X1, X2, X3 3

S17900-9

IC,CMOS,REGISTER,SHFT,SI/PO,8-BIT(SS)
X4

1

S17900-23

IC,CMOS ,FLIP-FLOP,D, DUAL,HC74(S S)
X5

1

S17900-8

IC,CMOS, INVERTER,S CHMITT,HE X,HC14A(S S)

REFER TO ELECTRONIC COMPONENT DATABASE FOR SPECIFICATIONS ON ITEMS LISTED BELOW

1

2

J7

N.A.
N.C.

N.B.
N.B.

N.B.

N.A.

2.

00

ALL COMPONENTS AND MATERIALS USED IN THIS
ASSEMBLY ARE TO BE RoHS COMPLIANT PER E4253

G-7

PC BOARD ASSEMBLY - METER PC BOARD - M15893-3

ELECTRICAL DIAGRAMS

G-7

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

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

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 pro-

vided 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.

IDEALARC® CV-305

G-8

SCHEMATIC - SNUBBER PC BOARD - S19687

ELECTRICAL DIAGRAMS

G-8

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

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

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.

IDEALARC® CV-305

C1

C2

C3

C4

C5

J 5

R1

R2

R3

TP1

TP2

TP3

TP4

TP5

TP6

M15370-4

SNUBBER

0

0

4.70±.0

4

1

2

MAKE

PER E1911-ROHS,MANUF

ACTURE WITHOUTE3032 (SOLDER

MASK)

ENCAPSULATE WITH E1844

TES

T

PER E2792-S

ALLC

OM

PONENTS AND

MAT

ERIALS USED IN THIS

ASS

EMB

LY ARE TO BE RoHS C

OMPLIANT

PER E4253.

NOTES:

N

.A. DONOTCO

ATWITHE

NCAPSULATIO

NMATER

IAL.

REFERENCES

QTY

PART NO. DESCRIPTION

C1, C2, C3 3

T11577-68

0.68 MFD /400 WVDC CAPACITOR

C4, C5 2

T11577-46K

.05/600V

N.A.

J5

1

S18248-8

HEADER

R1, R2, R3 3

T14648-25

10 5W

TP1, TP2, TP3 3

T13640-12K

38J

TP4, TP5 2

T13640-18

160J

TP6

1

T13640-16

80J

CAP ACITORS = MFD/ VOLTS
RES ISTORS = OHMS
INDUCTANCE = HENRYS

ITEM

REQ'D

PART NO. DESCRIPTION

1 1 SEE BLANK INFO. P.C. BOARD BLANK

N.A. 2 4

S14020-5

EXPANSION NUT

SCHEMATIC REFERENCE: S19687-4G0

3.00±.0

4

2.

70

.3

0

4.

40

.3

0

G-9

PC BOARD ASSEMBLY - SNUBBER PC BOARD - M15370-4

ELECTRICAL DIAGRAMS

G-9

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

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

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 pro-

vided 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.

IDEALARC® CV-305