Lincoln Electric CV-305 User Manual

IDEALARC CV-305

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

importantly, think before you act
and be careful.

®

For use with machine Code Numbers 11177, 11178

IM860

February, 2006

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

OPERATOR’S MANUAL

Copyright © 2006 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

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.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.

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.

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.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

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

ii

SAFETY

ii

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.

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

3.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.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

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

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

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

vapors

to

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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

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.

Remember that welding sparks and hot

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.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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

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

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.

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

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

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

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

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

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

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

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.

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.

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

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

vv

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi

TABLE OF CONTENTS

Page

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

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

Select Suitable Location ........................................................................................A-2

Input Connections..................................................................................................A-2

Field Installed Options ...........................................................................................A-3

Required Equipment - Control Cable Connections................................................A-3

Output Connections...............................................................................................A-3

Paralleling .............................................................................................................A-4

Connection of Auxiliary Equipment to Wire Feeder Receptacle............................A-4

________________________________________________________________________

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

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

Graphic Symbols ...................................................................................................B-2

General Description...............................................................................................B-3

Recommended Processes and Equipment ...........................................................B-3

Operational Features and Controls........................................................................B-3

Design Features ....................................................................................................B-3

Power Source Operation .......................................................................................B-3

Duty Cycle .............................................................................................................B-3

Controls and Settings ..................................................................................B-4 thru 5

Starting the Machine..............................................................................................B-6

Adjusting the Output Voltage using the Digital Meter ............................................B-6

Local/Remote Switch Operation ............................................................................B-6

Auxiliary Power......................................................................................................B-6

Overload Protection...............................................................................................B-6

________________________________________________________________________

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

Factory/Field Installed Options..............................................................................C-1

Compatible Lincoln Equipment..............................................................................C-1

________________________________________________________________________

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

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

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

Machine and Circuit Protection..............................................................................D-1

________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Built-in Diagnostic Routines and Error Codes -Troubleshooting Guide.................E-2

Machine -Troubleshooting Guide...........................................................................E-3

Options -Troubleshooting Guide............................................................................E-6

Procedure for Replacing PC Boards......................................................................E-7

Control and Meter PC Board Troubleshooting Procedures ...................................E-7

Output Voltage, Fault Protection, Snubber Circuit and K857 Remote Control Checks

________________________________________________________________________

Diagrams ..........................................................................................................Section F

________________________________________________________________________

Parts Manual............................................................................................................P511

________________________________________________________________________

....................E-8

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC CV-305

INPUT - THREE PHASE ONLY

Voltage, 60Hz

Current at Rated Output,

100% Duty Cycle

A-1

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)

330 lbs.

CV-305

A-2

INSTALLATION

A-2

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)

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.

CV-305

A-3

INSTALLATION

A-3

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

feeder 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%

Lengths up to

150 ft 150 to 200 ft

2/0 (70mm2) 3/0 (95mm

2

)

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

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

CV-305

A-4

INSTALLATION

PARALLELING

The CV-305 is not designed to be paralleled with itself
or 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.

A-4

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.

CV-305

B-1

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section before oper­ating the machine.

GENERAL WARNINGS

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK
can kill.

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

• Insulate yourself from work and
ground.

B-1

• 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 Safety Guidelines detailed
throughout this manual.

CV-305

B-2

OPERATION

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

THERMAL PROTECTION

OFF

INDICATOR LIGHT

B-2

ON

AC

POWER

REMOTE OUTPUT

VOLTAGE CONTROL

WARNING

CIRCUIT

BREAKER

CLOCKWISE ROTATION

INCREASES VOLTAGE

LOCAL OUTPUT

VOLTAGE CONTROL

INDICATES WARNING

INFORMATION LOCATED

ON RIGHT CASE SIDE

CV-305

B-3

CAUTION

OPERATION

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

B-3

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 the 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.

CV-305

B-4

OPERATION

CONTROLS AND OUTPUT SETTINGS

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

FIGURE B.1 - CONTROL AND OUTPUT PANEL

B-4

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).

CV-305

B-5

OPERATION

B-5

9. WIRE FEEDER VOLTMETER SWITCH

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

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

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.

+ Output connector is a Magnum Twist-Mate™,

receptacle. Insert a mating Twist-Mate™ plug,
and twist clockwise to secure.

11. LOW INDUCTANCE NEGATIVE CONNECTION.

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

12. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION.

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
voltmeter 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.

CV-305

B-6

OPERATION

B-6

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 auxil-

iary loads. (The 2-4 circuit is isolated from the
31-32 and 41-42 circuits.)

CAUTION

Note that some types of equipment, especially pumps
and large motors, have starting currents which are
significantly higher than their running current. These
higher starting currents may cause the circuit breaker
to open. If this situation occurs, the user should refrain
from using the CV-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 remote control, such as the K857 (see INSTALLA­TION section), 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.

CV-305

C-1

ACCESSORIES

C-1

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 availible 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)

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

LN-25

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

LN-742 / LN-742H Requires K591 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 wire feeder input
cable, such as a K480, with a Lincoln wire feeder.

TWIST-MATE CABLE PLUG (MALE)

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

• For 2/0-3/0 (70-95 mm2) Cable (K852-95)

TWIST-MATE CABLE RECEPTACLE
(FEMALE)

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

• For 2/0-3/0 (70-95 mm2) Cable (K1759-95)

CV-305

D-1

MAINTENANCE

D-1

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 CV­305 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.

CV-305

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

E-1

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.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

BUILT-IN DIAGNOSTIC ROUTINES AND ERROR CODES

The CV-305 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

E40

E50

TROUBLE REMEDY

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.

2. Remote Control not functioning
correctly.

Input line voltage too low.

Input line voltage too high.

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 still persists, call Local Lincoln

Authorized Field Service Facility.

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

See PC Board Troubleshooting Procedure.

1. Check wiring between Voltage Adjust and the

Control PC Board.

2. See Options Troubleshooting Guide.

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.

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).

Overload condition.

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 your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

MACHINE TROUBLESHOOTING GUIDE

Not all trouble conditions can be recognized by the PC board, and displayed as error codes. The following guide
covers most other trouble conditions.

PROBLEMS

(SYMPTOMS)

Machine has no output.

POSSIBLE

CAUSE

PROBLEMS

1. Secondary contactor circuit (2
and 4 wire feeder receptacle) not
working.

2. Electrode or work lead loose or
broken.

3. Defective PC Board.

4. Protective circuits operating due
to output short circuit.

5. If using an LN-25, K484 jumper
plug kit not making connection
between 2 & 4 in wire feeder
receptacle.

6. If welding with 1/16" aluminum
wire and machine is flashing E00.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Machine has minimum output and no
control.

Machine has low output and no con­trol.

1. Voltage Control misconnected.

1. Open in feedback circuitry.

2. Faulty PC Board.

3. Voltage Adjust potentiometer
circuit open (lead 75).

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Thermal Protection Indicator light is
on.

Machine does not have maximum
output

Machine will not shut off.

Variable or sluggish welding arc.

POSSIBLE

CAUSE

PROBLEMS

1. Thermostat circuit has opened.

2. Faulty Control PC Board.

1. Faulty Control PC Board.

2. Voltage Adjust potentiometer
defective.

3. Voltage Adjust potentiometer
leads open.

1. Defective power switch.

1. Poor work or electrode
connection.

2. Welding leads too small.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Digital meters do not light

- or -

Digital meter display is incorrect.

3. Welding current or voltage
too low.

4. Defective SCR bridge.

1. Faulty Meter PC board.

2. Faulty Control PC Board.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

(SYMPTOMS)

Output Control not functioning on the
machine.

Poor arc striking with semiautomatic
wire feeders.

POSSIBLE

CAUSE

PROBLEMS

1. Local/Remote switch is in
the "Remote" position.

2. Faulty Voltage Adjust
potentiometer.

3. Leads or connections open in
control circuit.

4. Malfunctioning Remote Control.

5. Faulty Control PC board.

1. Poor work connection.

2. Improper procedures.

3. Wire feed acceleration too fast or
too slow.

4. Defective PC Board.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Poor arc characteristics

1. Control PC Board defective.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-6

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

OPTIONS TROUBLESHOOTING GUIDE

K857 (or other) Remote Output Control

E-6

PROBLEMS

(SYMPTOMS)

Output control not functioning on
Remote Control.

Output Control not functioning on the
machine.

POSSIBLE

CAUSE

PROBLEMS

1. Local/Remote switch in wrong
position.

2. Faulty Local/Remote switch.

3. Faulty Remote Control poten­tiometer.

4. Leads or connections open in
control circuit.

5. Faulty Control PC board.

1. Local/Remote switch in the
wrong position.

2. Faulty Local/Remote switch.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

3. Faulty Voltage Adjust
potentiometer.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-7

TROUBLESHOOTING

E-7

Procedure for Replacing PC Boards

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified individual install and
service this equipment.

• Turn the power source input power off
at the disconnect switch before work­ing on this equipment.

• Do not touch electrically hot parts.

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

Before replacing a PC board which is suspected of
being defective, visually inspect the PC board in ques­tion for any electrical or mechanical damage to any of
its components and conductors on the back of the
board.

a. If there is no

install a new one and see if this remedies the prob­lem. If the problem is remedied, reinstall the old
PC board to see if the problem still exists. If it
does

no longer exist with old PC board:

1. Check the PC board harness connector pins for
corrosion, contamination, or looseness.

visible damage to the PC board,

PC BOARD TROUBLESHOOTING
PROCEDURES

CONTROL PC BOARD

The Control PC Board controls all machine functions
including the thermal protection indicator light and the
Meter PC Board. Most problems, if not caused by
faulty wiring machine misuse, will stem from a faulty
Control PC Board.

Perform the following diagnostic procedure before
replacing the Control PC Board.

1. Turn off the input power at the fuse box.

2. Check for loose connections in the PC Board
plugs, particularly J3.

3. Disconnect the J3 plug from the Control PC Board.
Measure the resistance between the following wire
terminals in the plug:

A) Between wire #200 and wire #201.

B) Between wire #202 and wire #203.

2. Check leads in the plug harness for loose or
intermittent connection.

b. If PC board is visibly damaged electrically

possibly subjecting the new PC board to the same
cause of failure, check for possible shorts, opens,
or grounds caused by:

1. Frayed or pinched lead insulation.

2. Poor lead termination, such as a poor contact
or a short to adjacent connection or surface.

3. Shorted or open motor leads, or other external
leads.

4. Foreign matter or interference behind the PC
boards.

c. If PC board is visibly damaged mechanically,

inspect for cause, then remedy before installing a
replacement PC board.

If there is damage to the PC board or if replacing
PC board corrects problem, return it to the local
Lincoln Electric Field Service Shop.

, before

Both of these resistances should be less than 1 ohm.

If these resistances are not less than 1 ohm, check the
wiring back to the main transformer.

If these voltages are less than 1 ohm, refer to
"Procedure for Replacing PC Boards."

METER PC BOARD

When the Meter PC Board malfunctions, first determine
if the rest of the machine functions correctly. If so, then
the problem is in either the harness between the meter
and control boards, or in the meter board itself. Refer
to "Procedure for Replacing PC Boards". As a last
resort, the Control PC Board may have to be replaced.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

E-8

TROUBLESHOOTING

OUTPUT VOLTAGE

The open circuit voltage of the machine should be 10
to 43 volts. If any other condition exists, refer to the
Troubleshooting Guide.

FAULT PROTECTION OPERATION

The overload protection circuit on the PC Board will
cause the CV-305 meter to display "E60". This pro­tection circuit will reset itself automatically. The short
circuit protection circuit will cause the meter to display
"E00". The CV-305 power switch must be turned
"OFF" and then "ON" to return the machine to normal
output.

CHECKING SNUBBER CIRCUIT

In case of an SCR malfunction or failure, the snubber
assembly should be checked. Disconnect the input
power to the CV-305 at the fuse box and remove the
right side of the machine.

E-8

1.Visually inspect the snubber PC Board assembly
(located below the Control PC board on the case front
for overheated components or damaged compo­nents).

OPTIONAL K857 REMOTE CONTROL
CHECK

Disconnect the remote output control and connect an ohm­meter between pins C and B and rotate the rheostat in the
remote control. The resistance reading should go from zero
to 10K ohms. Repeat with ohmmeter across A and B with
the same results. Connect ohmmeter across A and C. The
reading should be 10K ohms. A lower reading will indicate a
shorted or partially shorted rheostat. A very high reading
will indicate an open rheostat. In either of the last two
cases, replace the rheostat.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CV-305

12

34

1 3

4

6

CONNECTOR CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P. C. BOARD)

ELECTRICAL SYMBOLS

PER E1537

+

-

L1

SECONDARY

THERMOSTAT

222

223

224

D4

C1

C2

C3

C4

+

+

+

+

R1

SCR2

D2

D5

222

204A

204D

CONTROL

P. C. BOARD

221

6 PIN

4 PIN

8 PIN

1

4

8

SNUBBER/BYPASS

P.C. BOARD

5

224

224A

10A

CIRCUIT

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

10 PIN

5

6

10

S2

M

L

N

G

F

E

H

VOLTMETER

CUSTOMER

CONNECTIONS

WIRE

FEEDER

115 VAC

42 VAC

GROUND

WIRE

FEEDER

RECEPTACLE

205

WIRE FEEDER

S3

3

1

SCR3

D3

SCR1

D1

823

4

1

7

6

5

213A

213A

OUTPUT

CONTROL

208

209

210

1

2

3

4

J7

METER

P.C.

BOARD

VOLTS / AMPS

215

5

7

3

2

2

5

3

4

1

6

6

1

5

4

738

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

SHUNT

J10

1

2

2 PIN

J10

224B

224B

224B

(SHOWN IN "VOLTS" POSITION)

7.5 OHM

220 W

214B

214B

s

s

42A

42

41

42

I

K

C1-C4 31,000 MFD EACH

MAIN TRANSFORMER

C

2

41A

41

s

FAN

33A

31A

32

33

CIRCUIT

BREAKER

5A

CB2

115V

31B

31

8

6

10

9

***

200

203

201

s

s

58V

58V

O2 TOP

O1 TOP

O1 TOP

O3 TOP

O3 BOT.

VOLTMETER

SWITCH

76

77

75

77

76

277

276

S4

(SHOWN IN LOCAL POSITION)

LOCAL/REMOTE SWITCH

R2

10K

CW

376

77

377

376

377

N.A. WIRING VIEWED FROM REAR OF POTENTIOMETER

242

+

-

2

L2

INPUT SUPPLY

LINES

S1

LINE

SWITCH

*

RECONNECT

PANEL

11

E

8

5

2

V

N.B.

B

UW

L1 L3

***

3

3

C

9

6

F

12

10

1A4

7

D

RECONNECT

PANEL

2 3 1

TO S1 LINE SWITCH

RECONNECT

PANEL

RECONNECT

PANEL

RECONNECT

PANEL

RECONNECT

PANEL

RECONNECT

PANEL

208/230/460 INPUT VOLTAGES

230/460/575 INPUT VOLTAGES

208V 230V 460V

230V 460V 575V

2 3 1

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

2 3 1

{

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

A.0

4

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, AND C APPEAR ON THE TOP PRIMARY COILS

OF 208/230/460V MACHINES ONLY.

WIRING DIAGRAM CV-305 (60Hz)

TO A SYSTEM GROUND PER

NATIONAL ELECTRICAL CODE.

*

L12393

A.04

{{

{

{

{

POWER FACTOR

ENHANCEMENT

CHOKE

172

171

173

42B

L3

L4

L2

172

173

171

204A

202

200

203

201

219

218

218

219

WHITE

WHITE

RED

RED

L5

L6

320VAC

320VAC

.05uf

600V

.05uf

600V

206

205

202

275

4

213B

213B

213B

F-1

DIAGRAMS

F-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

CV-305

F-2

DIAGRAMS

CV POWER SOURCE TO AN LN-7 AND K857

LN-7/LN-7GMA

WIRE

FEEDER

ASSEMBLY

F-2

S20662

Modified 7/04

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

14 PIN

AMPHENOL

SHOCK

ELECTRIC

WARNING

CAN KILL

CV/CV-I

OPTIONAL K857

REMOTE CONTROL

N.C.

POWER SOURCE

K1818-10 INPUT CABLE

CONTROL ADAPTER

OPTIONAL K864 REMOTE

ELECTRODE CABLE

TO WORK

-

+

CV-305

CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE.

N.C. USE OF THE K857 REMOTE CONTROL REQUIRES THE INSTALLATION OF A K864 REMOTE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

F-3

DIAGRAMS

CV POWER SOURCE TO AK867 UNIVERSAL ADAPTER

N.F.

N.C.

N.D.

N.F.

N.E.

REMOTE OUTPUT CONTROL

{

TO

2

WIRE

TO

FEEDER

4

K867

6-18-93

S20658

F-3

CONNECT TOGETHER FOR

NOT USED ON CV/CV-I POWER SOURCES

2

82

81

SPARE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

WELDING OUTPUT

4

41

42 VAC

31

42

115 VAC

WIRE FEEDER VOLTMETER CONNECTION

POWER SOURCE FRAME CONNECTION

21

32

GND

AMPHENOL

K867 UNIVERSAL

ADAPTER PLUG

MIN.

10K

CONNECTS TO (WORK TERMINAL) OF POWER SOURCE

77

76

75

CV/CV-I

POWER SOURCE

-

+

CV-305

ELECTRODE CABLE

TO WORK

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

CURRENT DRAW.

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.

RELAY TO CLOSE LEADS 2 & 4.

N.F. NOT PRESENT ON ALL MACHINES

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION

F-4

DIAGRAMS

CV POWER SOURCE TO AK867 / K775 / LN-7

LN-7

WIRE

FEEDER

K291 OR K404

INPUT CABLE

K775 OPTIONAL

6-18-93

S20659

REMOTE CONTROL

F-4

N.C.

828142

SPARE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

41

31

31

32

32

21

GREEN

GND

757677

2

4

N.D.

2

4

21

K867 UNIVERSAL

757677

GND

ADAPTER PLUG

14 PIN

AMPHENOL

CV/CV-I

POWER SOURCE

-

+

CV-305

ELECTRODE CABLE

TO WORK

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.D. SPLICE LEADS AND INSULATE.

F-5

DIAGRAMS

CV POWER SOURCE TO AN LN-25

LN-25

WIRE FEEDER

REMOTE CONTROL

OPTIONAL K857

F-5

6-18-93

S20661

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

WARNING

ELECTRIC

CAN KILL

14 PIN

AMPHENOL

CV/CV-I

POWER SOURCE

N.C.

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

CONTROL ADAPTER

OPTIONAL K864 REMOTE

ELECTRODE CABLE

OPTIONAL

N.D.N.D.

K484 JUMPER

PLUG

TO WORK

-

+

CV-305

CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE.

IF USING A K857 REMOTE CONTROL,CONNECT THE K484 JUMPER PLUG

OF THE POWER SOURCE IF NO REMOTE CONTROL IS USED.

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.

N.C. USE OF THE K857 REMOTE CONTROL REQUIRES INSTALLATION OF A K864 REMOTE

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.D. CONNECT THE K484 JUMPER PLUG DIRECTLY TO THE 14 PIN AMPHENOL

TO THE 14 PIN AMPHENOL OF THE K864 REMOTE CONTROL ADAPTER.

THE POWER SOURCE WELDING TERMINALS ARE ALWAYS "HOT" WHEN THE K484 JUMPER

F-6

DIAGRAMS

CV POWER SOURCE TO AN LN-25 / K444-1

LN-25

WITH K444-1 OPTION

WIRE FEEDER

F-6

6-18-93

S20663

CLEVELAND, OHIO U.S.A.

CONTROL ADAPTER

OPTIONAL K864 REMOTE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

WARNING

ELECTRIC

CAN KILL

14 PIN

AMPHENOL

CV/CV-I

POWER SOURCE

N.D.N.D.

OPTIONAL

K484 JUMPER

PLUG

ELECTRODE CABLE

N.C.

TO WORK

-

+

K864 REMOTE CONTROL ADAPTER. CONNECT THE 6 PIN PLUG FROM THE

LN-25 (WITH K444-1 OPTION) TO THE 6 PIN RECEPTACLE OF THE K864

CV/CV-I POWER SOURCE TO LN-25 WITH K444-1 OPTION CONNECTION DIAGRAM

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. CONNECT THE K484 JUMPER PLUG TO THE 14 PIN RECEPTACLE OF THE

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

PLUG KIT IS INSTALLED.

REMOTE CONTROL ADAPTER. SWITCH THE POWER SOURCE "LOCAL/REMOTE" SWITCH TO REMOTE.

N.D. THE POWER SOURCE TERMINALS ARE ALWAYS "HOT" WHEN THE K484 JUMPER

CV-305

F-7

DIAGRAMS

LINCOLN POWER SOURCE TO AN LN-742

K=42

F-7

S20409

Modified 7/04

C=2

D=4

E=77

service this machine.

Only qualified persons should install, use or

Power Source before connecting the wire feeder.

Turn off (0) the power switch on the Welding

SHOCK

ELECTRIC

N.D.

14 PIN

CAN KILL

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND DUTY CYCLE OF APPLICATION.

LN-742

WIRE

FEEDER

AMPHENOL

WARNING

I=41

H=21

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO

CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT

POWER SOURCE AND SET WIRE FEEDER

VOLTMETER POLARITY SWITCH ON POWER

SOURCE TO PROPER POLARITY.

K1819-10

N.D. IF USING K589-1, REMOTE CONTROL KIT,

SET POWER SOURCE CONTROL SWITCH

N.C. PINS NOT LISTED ARE NOT CONNECTED

ON CABLE.

LN-742

INPUT CABLE

TO "REMOTE" POSITION.

I=41

K=42

ASSEMBLY

H=21

C=2

G=75

G=75

D=4

F=76

14-SOCKET BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

F=76

E=77

14-SOCKET BOX RECEPTACLE, FRONT VIEW

AND 14-PIN CABLE PLUG, REAR VIEW

LINCOLN

POWER SOURCE

+

ELECTRODE CABLE

TO WORK

WORK

FUNCTION

TRIGGER CIRCUIT

OUTPUT CONTROL

TRIGGER CIRCUIT

OUTPUT CONTROL

OUTPUT CONTROL

42V AC

42V AC

-

2

CV-305

4

77

LEAD

PIN

C

FUNCTIONS ARE LISTED FOR REFERENCE

(SEE APPROPRIATE WIRING DIAGRAM)

ONLY AND EACH MAY OR MAY NOT BE

PRESENT IN YOUR EQUIPMENT.

76

F

E

D

75

G

21

H

41

I

42

K

F-8

DIAGRAMS

K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS

L=82

C=2

B=GND

A=32

D=4

E=77

S19386

3-16-90

F-8

INSTALLATION INSTRUCTIONS

K=42

K=42

J=31

J=31

A=32

I=41

I=41

B=GND

H=21

N=SPARE

H=21

L=82

C=2

G=75

N=SPARE

G=75

D=4

F=76

F=76

E=77

M=81

14-PIN BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

M=81

AND 14-PIN CABLE PLUG, REAR VIEW

14-PIN BOX RECEPTACLE, FRONT VIEW

MAY OR MAY NOT BE ISOLATED, INDEPENDENT CIRCUITS INSIDE THE WELDER.

TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.

WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS

THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN

THIS ADAPTER TO WIRE FEEDER CABLE.

1. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING

CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.

NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.

NOTE: 115V AC (31, 32), 42V AC (41, 42), 24V AC (SPARE) AND TRIGGER CIRCUIT (2, 4)

THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.

2. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.

IN THE UNIVERSAL ADAPTER. THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.

3. USE LUG, CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD
STANDARD FUNCTION

115V AC

CHASSIS CONNECTION

TRIGGER CIRCUIT

OUTPUT CONTROL

TRIGGER CIRCUIT

2

4

32

GND

LEAD

B

A

PIN

REFERENCE ONLY AND EACH MAY OR

(SEE APPROPRIATE WIRING DIAGRAM)

MAY NOT BE PRESENT IN YOUR EQUIPMENT.

THESE FUNCTIONS ARE LISTED FOR

77

E

C

D

WORK

OUTPUT CONTROL

OUTPUT CONTROL

21

76

75

F

H

G

115V AC

42V AC

41

31

I

J

42V AC

42

K

WELDING MODE CONTROL

WELDING MODE CONTROL

81

82

L

M

CV-305

24V AC

SPARE

N

F-9

DIAGRAMS

TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS

TWIST-MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS

TURN THE POWER SWITCH OF THE WELDING POWER
SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO
WELDING POWER SOURCE.

CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE

1.
APPROPRIATE CABLE SIZE PER TABLE BELOW; AND

SKIN CABLE JACKET TO LENGTH SPECIFIED:

F-9

BOOT MARKING

35-50

50-70

70-95

2.

If necessary, trim cable end of boot at groove(s) to match cable

diameter. Boot must fit tightly enough to seal around outside
diameter of cable. NOTE: Some boots are designed to accommodate

different cable diameters without trimming. These boots do not

have grooves at the cable end. Soap or other non petroleum

based lubricant will help to slide the boot over the cable.

Slide rubber boot onto cable end.

3.

WELDING CABLE

Slide the copper tube into the brass plug.

4.

Insert cable into copper tube.

5.

AMERICAN (EUROPEAN) RANGE

CABLE SIZE

#2-#1

1/0-2/0

2/0-3/0

SEE

ABOVE

(

35-50

(

50-70

70-95

(

mm )

mm )

mm )

TRIM

2

2

CABLE SKIN LENGTH

1 INCH (25.4mm)

2

1 INCH (25.4mm)

1.5 INCH (38.1mm)

BOOT

SET SCREW
(70-95 size may

have 2 set
screws)

COPPER TUBE

Tighten set screw(s) to collapse copper tube. Screw(s)

6.
must apply firm pressure against welding cable. The top of the

set screw(s) will be nearly flush or below the surface of the

brass plug after tightening.

Slide rubber boot over brass plug. The rubber boot must be

7.
positioned to completely cover all electrical surfaces after

the plug is locked into the receptacle.

CV-305

BRASS PLUG

9-20-91J

S18737

F-10

DIAGRAM FOR WIRE FEEDERS THAT CLOSE A

SET OF CONTACTS TO GET POWER SOURCE OUTPUT:

4 2

31 32 41 42 75 76 77GND

OUTPUT

CONTACTOR

CONTROL

115 V.A.C.

SUPPLY

42 V.A.C.

SUPPLY

N.B.

N.A.

N.A.

N.A.

DIAGRAM FOR WIRE FEEDERS THAT SUPPLY A

VOLTAGE TO GET POWER SOURCE OUTPUT:

LINCOLN POWER SOURCE 14-PIN WIRE FEEDER

RECEPTACLE WITH K867 UNIVERSAL ADAPTER

CONTACTS CLOSE

TO GET POWER

SOURCE OUTPUT

WIRE FEEDER

INPUT POWER

REMOTE OUTPUT

CONTROL

(IF SO EQUIPPED)

}

}

}

}

}

}
}

N.D.

NON-LINCOLN WIRE FEEDER

GND

10 K OHM

MIN.

MAX.

4 2

31 32 41 42 75 76 77GND

OUTPUT

CONTACTOR

CONTROL

115 V.A.C.

SUPPLY

42 V.A.C.

SUPPLY

N.B.

N.A.

LINCOLN POWER SOURCE 14-PIN WIRE FEEDER

RECEPTACLE WITH K867 UNIVERSAL ADAPTER

VOLTAGE SUPPLIED

TO GET POWER

SOURCE OUTPUT

WIRE FEEDER

INPUT POWER

REMOTE OUTPUT

CONTROL

(IF SO EQUIPPED)

}

}

}

}

}

}

}

N.D.

NON-LINCOLN WIRE FEEDER

GND

10 K OHM

MIN.

MAX.

RELAY CONTACT

(NORMALLY OPEN)

RELAY COIL

N.C.

RELAY

N.A. CONNECTIONS 31 AND 32 MAY NOT BE PRESENT ON ALL MACHINES.

N.B. POWER SOURCE MUST BE PROPERLY GROUNDED.

N.C. RELAY COIL MUST BE RATED FOR THE SAME VOLTAGE THAT IS SUPPLIED BY

THE WIRE FEEDER.

N.D. IF THE WIRE FEEDER REQUIRES AN INPUT VOLTAGE OTHER THAN 42 V.A.C.,

OR 115 V.A.C. ON SOME MACHINES, AN EXTERNAL POWER SUPPLY FOR THAT

VOLTAGE MUST BE PROVIDED.

DIAGRAMS

CONNECTION OF NON-LINCOLN WIRE FEEDERS

F-10

CV-305

F-11

3.90 (99)

11.99 (304)

41.58 (1056)

.28

(7.0)

12.60 (320)

DIAGRAMS

DIMENSION PRINT

N.A.

F-11

M15665

5-18-90J

1.00 (25.4)

23.62 (600)
WELDER DOWN USING 5/16 SCREWS

26.00 (660)

3.61 (91)

1.68
(42.7)

N.B.

24.75

(628)

21.50 (546)

30.95

(786)

N.A.

6.20 (157)

N.B. HANDLE CONFIGURATION ON EARLIER MODELS.

N.A. FOUR SLOTS IN BASE FOR MOUNTING

1.38

(35)

19.65 (499)

20.05 (509)

19.20 (487)

N.A.

17.25 (438) (CENTERED)

CV-305

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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