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RETURN TO MAIN MENU
IM481-B
CV 500-I
February, 2011
For use with machines Codes 10088 thru 10092, 10277, 10278, 11356
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• 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
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Summary of Contents for Lincoln Electric IM481-B
- Page 1 RETURN TO MAIN MENU IM481-B CV 500-I February, 2011 For use with machines Codes 10088 thru 10092, 10277, 10278, 11356 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 ...
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Page 2: Safety Precautions
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. - Page 3 SAFETY...
- Page 4 SAFETY...
- Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Thank You...
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Page 7: Table Of Contents
TABLE OF CONTENTS Safety Precautions ...2-5 Introductory Information ...7 Meaning of Graphic Symbols ...8-11 General Machine Description...12 Recommended Processes & Equipment ...12 Design Summary ...12 Operational Features & Controls ...12-14 Technical Specifications ...15 Installation ...16-18 Safety Precautions ...16 Location ...16 Application Limitations...16 Stacking...16 Input Power Connections ...16... -
Page 8: Meaning Of Graphic Symbols
MEANINGS OF GRAPHIC SYMBOLS The CV 500-I nameplate has been designed to use international symbols in describing the function of the various components. Below are the symbols used. POWER ON-OFF SWITCH OUTPUT CONTROL DIAL OUTPUT CONTROL “LOCAL-REMOTE” SWITCH Input (Power) Output Voltage Control (Export Model) Output Voltage Control (European Model) Increase / Decrease of Output Voltage... - Page 9 CIRCUIT BREAKER THERMAL PROTECTION LIGHT VOLTMETER SWITCH Circuit Breaker High Temperature Voltmeter Positive Electrode Negative Electrode – –...
- Page 10 RATING PLATE NEMA EW 1 IEC 974-1 IP21 Designates welder complies with National Electrical Manufacturers Association requirements EW 1. (Export Model only) Designates welder complies with International Electrotechnical commission requirements 974-1. (European model only) Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding...
- Page 11 WARNING IDENTIFICATION EARTH GROUND CONNECTION CHASSIS GROUND CONNECTION Warning Identification Signifying the Earth (Ground) Connection Signifying the Chassis (Ground) Connection – –...
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Page 12: General Machine Description
GENERAL MACHINE DESCRIPTION The CV 500-I is an SCR controlled three phase DC power source. It is designed with a single range potentiometer control. The CV500-I has two models - an Export model and a European model. The Export model complies with NEMA EW 1 requirements and the European model complies with IEC 974-1 requirements. - Page 13 AUXILIARY POWER CONNECTIONS The power source is equipped to furnish nominally 115 volt AC and 42 volt AC auxiliary power for operat- ing wire feeding equipment, etc. The auxiliary power is available at the 14-pin MS-style connector recepta- cle on the control panel and/or at a terminal strip behind the hinged control panel on the front of the power source.
- Page 14 PARALLELING There are no provisions on the CV 500-I to permit par- alleling. DIODE OPTION (Factory installed only) The CV 500-I Diode option is required to utilize the cold start and cold electrode sensing features of the NA-3, NA-5 or NA-5R. When this option is not used with an NA-3, NA-5 or NA-5R, see the CV 500-I / NA-3, CV 500-I / NA-5 or CV 500-I / NA-5R connection diagram for instructions on how to disable this circuit.
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Page 15: Technical Specifications
TECHNICAL SPECIFICATIONS Model Type Frequency Output Rating Amperes Volts NEMA EW1 IEC 974-1 Duty Cycle Output Range (Min.) (Max.) Max. O.C.V. Input Ratings Standard Voltages Single Voltages (Available) Rated Current Input kVA Power Factor Efficiency Idle Current Idle Power Optional Features Remote Control Adapter Cable 115V Starter Circuit Suitable Undercarriages... -
Page 16: Installation
INSTALLATION 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. • Always wear dry insulating gloves. ------------------------------------------------------------------------ FUMES AND GASES can be danger- ous. -
Page 17: Output Cable Connections
C UTION Failure to follow these instructions can cause immedi- ate failure of components within the machine. When powering welder from a generator be sure to turn off the welder first, before generator is shut down in order to prevent damage to welder. Output Cable Connections The output leads are connected to the output termi- nals marked “... -
Page 18: Installation Of Equipment Required For Recommended Processes
Refer to “115VAC and 42VAC Auxiliary Power and Control Connections” section for connector pin functions. A cover (Lincoln Electric Part Number S17062-3) is available for the unused 14-pin connector to protect it against dirt and moisture. For control cable with terminal strip connectors:... -
Page 19: Operating Instructions
OPERATING INSTRUCTIONS Safety Precautions WARNING ELECTRIC SHOCK • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • This next section applies to CV 500-I’s without the Capacitor Discharge Option: --------------------------------------------------------------------- When using a CV 500-I power source with wire feed-... - Page 20 OUTPUT CONTROL “LOCAL-REMOTE” SWITCH The Output Control toggle switch on the control panel labeled “Local-Remote” gives the operator the option of controlling the output at the machine control panel or at a remote station. For remote control, the toggle switch is set in the “Remote” position and controlled at the wire feed unit control, or by connecting a K775 control to terminals 75, 76, and 77 on the terminal strip at the front of the machine, or by connecting a...
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Page 21: Maintenance
220 VAC AUXILIARY POWER FOR WATER COOLER A Continental European receptacle (220V Schuko type) is located on the rear panel for supplying 220VAC to a water cooler. A 2 amp circuit breaker which is also located on the rear panel protects this circuit from excessive overloads or short circuits. -
Page 22: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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. - Page 23 TROUBLESHOOTING GUIDE Trouble Input contactor (CR1 chatters). Machine input contactor does not operate. Machine input contactor operates, but no output when trying to weld. Machine has minimum output and no control. Machine has high output and no control. Cause 1. Faulty input contactor (CR1). 2.
- Page 24 Trouble Machine has low output and no con- trol. Machine does not have maximum output. Machine will not shut off. Variable or sluggish welding arc. Output control not functioning on the machine. Cause 1. Output Control “Local-Remote” switch (S2) in wrong position. 2.
- Page 25 Trouble Output control not functioning on “Remote” control. Poor arc striking with semiautomatic or automatic wire feeders. Poor arc characteristics. Cause 1. Output Control switch in wrong position. 2. Faulty Output Control switch. 3. Faulty remote control poten- tiometer. 4. Leads or connections open in control circuit.
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Page 26: Procedure For Replacing Pc Boards
Procedure for Replacing PC Boards WARNING ELECTRIC SHOCK • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. --------------------------------------------------------------------- When a PC board is suspected to be defective, the following procedure must be followed: 1. -
Page 27: Remote Control & System Checks
REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohmmeter across 75 and 76 and rotate the rheostat in the remote control. The resistance reading should go from zero to 10K ohms. Repeat with ohmmeter across 77 and 76 with same results. Connect ohmmeter across 75 and 77. -
Page 28: Twist Mate Welding Cable Plug Instructions
b a s e d l u b r i c a n t w i l l h e l p t o s l i d e t h e b o o t o v e r t h e c a b l e . S O U R C E "... -
Page 29: Diagrams
SCR1 Gate leads plug to Control P.C. board POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD ANODE CATHODE SCR2 SCR3 GATE – – To (+) side of capacitor bank ANODE CATHODE SHUNT POWER RECTIFIER BRIDGE DIAGRAM 1 CATHODE SCR2 PLUG TO SNUBBER BOARD ANODE SCR1... -
Page 30: Diagrams
Enhanced Diagram – –... - Page 31 NOTES...
- Page 32 NOTES...
- Page 35 • 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...