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For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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 thought-
ful 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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• Sales and Service through Subsidiaries and Distributors Worldwide •
The Lincoln Electric Company (Australia) Pty. Ltd. 35 Bryant Street, Padstow, Sydney 2211, Australia Phone: (02) 9772-7222 FAX: (02) 9792-1387
CV-525
A1677
IEC 60974-1
IP 21S
S
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
IM770
September, 2002
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Table of Contents
Related Manuals for Lincoln CV-525
Summary of Contents for Lincoln CV-525
- Page 1 Copyright © 2002 Lincoln Global Inc. • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • The Lincoln Electric Company (Australia) Pty. Ltd. 35 Bryant Street, Padstow, Sydney 2211, Australia Phone: (02) 9772-7222 FAX: (02) 9792-1387...
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Page 2: California Proposition 65 Warnings
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: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
- Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 50 199 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
- Page 7 SAFETY ELECTROMAGNETIC COMPATIBILITY (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations.
- Page 8 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.
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Page 9: Table Of Contents
viii viii TABLE OF CONTENTS Page Installation........................Section A Technical Specifications .......................A-1 Safety Precautions.......................A-2 Selected Suitable Location....................A-2 Application Limitations ....................A-2 Stacking ........................A-2 Input Power Connections ....................A-2 Outout Cable Connections ....................A-3 Installation of Field Installed Options ................A-3 Capacitor Discharge Circuit ..................A-3 Installation of Equipment for Recommended Processes ..........A-4 ________________________________________________________________________________ Operation.........................Section B... -
Page 10: Installation
INSTALLATION TECHNICAL SPECIFICATIONS CV-525 KA1454-1, KA1454-2 INPUT - THREE PHASE ONLY Input Current at Rated Output Standard Voltage 45% Duty Cycle 100% Duty Cycle 60% Duty Cycle 50% Duty Cycle 380-415V/50/60Hz (KA1454-1) 81/47/40 83/48/41 84/49/42 77/45/39 220/380-415/440V/50/60Hz (KA1454-2) RATED OUTPUT... -
Page 11: Safety Precautions
• Be sure machine is stable when lifting. before working on this equipment. • Do not stack more than three high. • Do not stack the CV-525 on top of any other • Turn the Power switch on the CV-525 “OFF” machine. -
Page 12: Installation Of Field Installed Options
This circuit mounts inside the CV-525 and is 150-200 ft Recommended when: (46-61 m) 85 mm 85 mm 1) CV-525 is used in conjunction with any LN-23P or 200-250 ft older LN-8 or LN-9 semiautomatic wire-feeder. (67-76 m) 107 mm 107 mm Eliminates possible arc flash re-start of weld when trigger interlock is used. -
Page 13: Installation Of Equipment For Recommended Processes
Only one wire feeder should be connected to the a) Turn off all power. CV-525 power source. If two or more are connected to the CV-525 power source it will not work properly. b) Connect the ARCWELD AWF or Panasonic Style wire feeder to WF-AWF/P receptacle. -
Page 14: Operation
OPERATION MEANINGS OF GRAPHIC SYMBOLS The CV-525 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 Input (Power) OUTPUT CONTROL DIAL Output Voltage Control (Export Model) Increase / Decrease of Output Voltage OUTPUT CONTROL “LOCAL-REMOTE”... - Page 15 Positive Electrode Negative Electrode WARNING IDENTIFICATION Warning Identification EARTH GROUND CONNECTION Signifying the Earth (Ground) Connection CHASSIS GROUND CONNECTION Signifying the Chassis (Ground) Connection SYMBOLS USED ON NAMEPLATES, AREAS ON THE MACHINE AND IN THIS MANUAL Gas Purge Crater Current CV-525...
- Page 16 OPERATION Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding Crater Voltage Wire Feeder Spot Weld 2-Step 4-Step Burn Back Run In Speed CV-525...
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Page 17: Safety Precautions
SAFETY PRECAUTIONS GENERAL DESCRIPTION Read and understand this entire section before oper- The CV-525 is an SCR controlled DC power source with a single range potentiometer control of the voltage out- ating the machine. put. The primary voltage is 380-415VAC 50/60Hz for sin-... -
Page 18: Input Contactor
The output terminals are recessed on the case front breaker. A toggle switch on the control panel selects and labeled “+” and “-”. The CV-525 provides stud ter- 115V AC or 42V AC to the receptacle. minals for output cables. - Page 19 OPERATION CV-525...
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Page 20: Solid Sate Output Control
NA-5R. When this option is not used with an NA-3, NA-5 or which hinges down for easy access to the board. The NA-5R, see the CV-525 / NA-3, CV-525 / NA-5 or CV-525 / Snubber PC Board is mounted on the back of the case NA-5R connection diagram for instructions on how to dis- front. -
Page 21: Power Source Operation
The three feeder receptacles are for Lincoln’s existing wire feed- When using a CV-525 power source with wire feeders, ers, ARCWELD AWF wire feeder/Panasonic style there will be a small spark if the electrode contacts the and OTC style wire feeders. - Page 22 0.25 – 5 seconds. The control is calibrated from 1 to 10. 14. WF-L FEEDER CONNECTIONS This connection is a Lincoln standard 14-pin receptacle for a 22. RUN-IN SPEED CONTROL Wire Feeder - (Lincoln standard feeder cable connection) The Run-In Speed Control allows having a slower wire speed before the arc strikes for starting optimization.
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Page 23: Control Features On Feeder Interface Board
Otherwise it is disabled. 5. FIXED BURN-BACK OUTPUT LEVEL The voltage output is reduced to 67% of the preset level during burn-back time. It minimizes the ball size at the front of the wire. CV-525... -
Page 24: Accessories
ACCESSORIES The CV-525 can be used to power any of the following Lincoln Wire feeders: SEMI-AUTOMATIC WIRE FEEDERS LN-9* LN-9 GMA • • LN-7 GMA* LN-23P • • LN-742 LN-25 • • LN-7 LN-8 • • Arcweld AWF-2 • Arcweld AWF-4 •... -
Page 25: Maintenance
3. Periodically check the welding cables. Inspect for any slits or punctures. Also make sure that all con- nections are tight. CV-525... -
Page 26: 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. - Page 27 5. 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-525...
- Page 28 4. Defective main SCR bridge. 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-525...
- Page 29 6-pin connection. 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-525...
- Page 30 DIAGRAMS CV-525 WIRING DIAGRAM PRIMARY CONNECTION TABLE PRIMARY VOLTAGE CONNECTION DAIG. 380-415V. 50/60Hz. AT3164-11 TO SUPPLY LINES 220 / 380-415 / 440V 50Hz. AM3237-1 230 / 380-415 / 460V 60Hz. CONTACTOR J9, J10, J14 J4, J11, J12 J1, J3, J7...
- Page 31 DIAGRAMS POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD ANODE To (+) side of capacitor bank CATHODE ANODE SCR1 SCR2 SCR3 GATE CATHODE SHUNT Gate leads plug to Control P.C. board To plug To T1 main transformer CV-525...
- Page 32 NOTES CV525...
- Page 33 NOTES CV-525...
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Page 34: Parts
● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE... - Page 35 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING ● Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish ● Los humos fuera de la zona de res- ●...
- Page 36 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • The Lincoln Electric Company (Australia) Pty. Ltd. 35 Bryant Street, Padstow, Sydney 2211, Australia Phone: (02) 9772-7222 FAX: (02) 9792-1387...