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: 888.935.3877 FAX: 216.486.1751 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
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