Lincoln Electric IM500 User Manual

10180, 10181

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IDEALARC CV-300

IM500-A

November, 2012

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.

For use with machine Code Numbers

OPERATORʼS MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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. D o not add the fuel near an ope n 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.

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. Weld ing 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.

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.

vapors

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.

iii

SAFETY

iii

WELDING and CUTTING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use onl y co m pressed 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. Re ad an d follow th e i ns tr uctions on co mp re ssed 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. Ins tall 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.

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent 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 lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres 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 dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils 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 dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc 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 nʼimporte quelle partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, 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 lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼ interieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

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

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

CUSTOMER ASSISTANCE POLICY

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___________________________________________________________________________

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

Your Product”. 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 “Support” and then “Register

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.

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

General Description...............................................................................................B-2

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

Operational Features and Controls........................................................................B-2

Design Features ....................................................................................................B-2

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

Power Source Operation .......................................................................................B-2

Duty Cycle .............................................................................................................B-2

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

Graphic Symbols ...................................................................................................B-4

Output Panel Connections.....................................................................................B-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 List.................................................................................................................P-271

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

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC CV-300

INPUT - THREE PHASE ONLY

Standard

Voltage

208/230/460/3/60

Input Current at

Rated Output

100% Duty Cycle 66/60/30

60% Duty Cycle 67/61/31

A-1

Code

Number

10180

230/460/575/3/60

Duty Cycle

100% Duty Cycle

NEMA Class I (100)

60% Duty Cycle

100% Duty Cycle

Welding Current/Voltage Range

(Continuous)

50A/7V - 400A/37V

Efficiency at 100% Load

78%

Idle Power

800W

100% Duty Cycle 60/30/24

60% Duty Cycle 61/31/25

RATED OUTPUT

Amps

300

400 300

OUTPUT

Normal Open Circuit Voltage

10-43

MAX OCV: 50

MISC. INFORMATION

Input kVA

60% Load - 24.1

100% Load - 23.8

Power Factor at 100% Load

.61

10181

Volts at Rated Amperes

36 32

Auxiliary

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

( Both Circuit Breaker Protected)

Idle Current - Amps

Power

11/10/5

PHYSICAL DIMENSIONS

Height Width Depth Weight

21.5 in. 19.5 in. 27.0 in. (Lift bail, add 3.12 in) 300 lbs

(137 kg)

546 mm 495 mm 686 mm

(Lift bail, add 80 mm)

CV-300

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-300 “OFF” before connecting or disconnecting output cables, wire feeder or remote connections, or other equipment.

• Do not touch electrically hot parts.

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

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-300 power sources carry an IP23 enclosure rating. They are rated for use in damp, dirty environments subject to occasional falling water such as rain.

STACKING

The CV-300 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-300 above it.

TILTING

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

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

200/50/60

220/50/60

230/50/60

380/50/60

400/50/60

415/50/60

440/50/60

500/50/60

circuit breakers may be used in place of

Fuse

(Super Lag)

or Breaker

Size

100

Input

Ampere

Rating on

Nameplate

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes

4 (25 mm2)

10 (6mm2)

4 (25 mm2)

8 (10mm2)

10 (6mm2)

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

8 (10mm2)

10 (6mm2)

8 (10mm2)

10 (6mm2)

CV-300

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.

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.

LN-7 to CV-300

a) Turn the CV-300 Power switch to the "OFF" posi-

tion.

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

receptacle on the CV-300.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

LN-25 to CV-300

a) Turn the CV-300 Power switch to the "OFF" posi-

tion.

b) Plug a K484 jumper plug into the CV-300 wire

feeder receptacle.

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

Output cables must have Magnum Twist-Mate™ plugs for connection to the CV-300. 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

300 A 100% (400 A 60%)

Lengths up to

150 ft 150 to 200 ft

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

)

WARNING

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

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

LN-742 to CV-300

a) Turn the CV-300 Power switch to the "OFF" posi-

tion.

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

feeder receptacle on the CV-300.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

CV-300

A-4

INSTALLATION

PARALLELING

The CV-300 is not designed to be paralleled 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-300 power source, for details on making those connections. For your convenience, wire feeder connection details are shown in the DIAGRAM section.

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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 CV300 and the wire feeder WITHOUT the need for a K867 Universal Adapter.

CV-300

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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.

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• 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-300

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OPERATION

CAUTION

When using a CV-300 power source with wire feeders, there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger.

When 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.

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• Circuit breaker protected.

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

• 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

GENERAL DESCRIPTION

The CV-300 is a constant voltage DC power source designed for the GMAW process with limited FCAW capability as well. It features an industrial rating of 300 amps, 32 volts, at 100% duty cycle. It complies with the requirements for a NEMA Class I (100) power source.

It is available from the factory in one model only, with no options other than input voltage or frequency.

RECOMMENDED PROCESSES AND EQUIPMENT

The CV-300 is capable of solid wire welding within the rated output capacity of the machine. It is also capable of welding with the following flux-cored wires: NR152, NR-211, NS-3M, NR-203 Ni 1%, and Outershield® 70 and 71.

The CV-300 is recommended for use with the LN-7, LN-742 and LN-25 wire feeder models.

• "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.

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

LIMITATIONS

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.

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

The CV-300 is intended only for use with the following FCAW electrodes: NR-152, NR-211, NR-203 Ni 1%, NS-3M, Outershield 70 and 71. The machine has been designed primarily for the GMAW process.

POWER SOURCE OPERATION

Be sure the CV-300 is properly installed, and that all accessories are properly hooked up before attempting operation.

DUTY CYCLE

300 Amps, 32 Volts at 100% 400 Amps, 36 Volts at 60%

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

CV-300

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