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Lincoln Electric idealarc CV305 Operator's Manual

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Operator's Manual
Idealarc CV305
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM480-D
| Issue D ate Jul-17
© Lincoln Global, Inc. All Rights Reserved.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric idealarc CV305

  • Page 1: Safety Precautions

    Operator’s Manual Idealarc CV305 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).

  • Page 4: Electric Shock Can Kill

    S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Safety Precautions......................2-5 Introductory Information....................... 7 Meaning of Graphic Symbols.................... 8-11 General Machine Description....................12 Recommended Processes & Equipment................12 Design Summary......................12-14 Operational Features & Controls................12-14 Technical Specifications..................... 15 Installation........................16-18 Safety Precautions....................... 16 Location........................16 Stacking........................16 Input Wiring........................

  • Page 7: Meaning Of Graphic Symbols

    MEANINGS OF GRAPHIC SYMBOLS The CV-400 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) Increase/Decrease of Output (Voltage) OUTPUT CONTROL “LOCAL-REMOTE”...
  • Page 8 CIRCUIT BREAKER Circuit Breaker THERMAL PROTECTION LIGHT High Temperature VOLTMETER SWITCH Voltmeter Positive Electrode Negative Electrode – –...
  • Page 9 RATING PLATE NEMA EW 1 Designates welder complies with National Electrical Manufacturers Association requirements EW 1. Three Phase Power Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Flux Cored Arc Welding IP21 Degree of protection provided by the enclosure –...
  • Page 10 WARNING IDENTIFICATION Warning Identification EARTH GROUND CONNECTION Signifying the Earth (Ground) Connection CHASSIS GROUND CONNECTION Signifying the Chassis (Ground) Connection – –...

  • Page 11: General Machine Description

    GENERAL MACHINE DESCRIPTION MACHINE OUTPUT CONTROL SWITCH “LOCAL” OR “REMOTE” The CV-400 is an SCR controlled three phase DC The machine output voltage can be controlled by power source. It is designed with a single range either the “OUTPUT COnTROL” on the machine con- potentiometer control.
  • Page 12 AUXILIARY POWER CONNECTIONS SOLID STATE CONTROL SYSTEM The power source is equipped to furnish nominally The Control PC Board is located behind the control 115 volt AC and 42 volt AC auxiliary power for operat- panel which hinges down for easy access to the ing wire feeding equipment, etc.
  • Page 13 PARALLELING There are no provisions on the CV-400 to permit par- alleling. DIODE OPTION (Factory installed only) The CV-400 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-400 / nA-3, CV-400 / nA-5 or CV-400 / nA-5R connection diagram for instructions on how to disable this circuit.

  • Page 14: Technical Specifications

    TECHNICAL SPECIFICATIONS Model CV-400 Type K1346 Frequency 60 Hz Output Rating Amperes Volts nEMA EW1 IEC 974-1 Duty Cycle 60% 100% Output Range (Min.) 60A 12V (Max.) 500A 42V Max. O.C.V. Input Ratings 230/460 Standard Voltages 230/460/575 Single Voltages (Available) Rated Current 77A @ 400A 34V (230V) Input kVA 30.7 @ 400A 34V...

  • Page 15: Installation

    INSTALLATION APPLICATION LIMITATIONS There are no provisions on the CV-400 for paralleling, Safety Precautions and outdoor operations without rain sheltering is not WARNING recommended. ELECTRIC SHOCK can kill. LIMIT ON STACKING • Do not touch electrically live parts or WARNING electrode with skin or wet clothing. •...

  • Page 16: Output Connections

    CAUTION REMOTE CONTROL ADAPTER CABLE (K864) Failure to follow these instructions can cause immedi- ate failure of components within the machine. S T R A I G H T P L U G ( 1 4 P I N ) C A B L E R E C E P TA C L E ( 6 S O C K E T ) When powering welder from a generator be sure T O P O W E R S O U R C E...

  • Page 17: 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 18: Operating Instructions

    OPERATING INSTRUCTIONS POWER SOURCE OPERATION Safety Precautions Duty Cycle and Time Period WARNING ELECTRIC SHOCK The CV-400 is rated at the following duty cycles: can kill. • Have an electrician install and service this equipment. Duty Cycle* Amps Volts • Turn the input power off at the fuse box before working on equipment.

  • Page 19: To Set Polarity

    OUTPUT CONTROL “LOCAL-REMOTE” SWITCH FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE 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 K = 4 2 or at a remote station. For remote control, the toggle A = 3 2 J = 3 1 switch is set in the “Remote”...

  • Page 20: Maintenance

    MAINTENANCE Terminal Strip Connections WARNING Terminal strip TS2 located behind the hinged control ELECTRIC SHOCK panel on the front of the power source supplies 115 can kill. VAC. A 10 amp circuit breaker protects this circuit. • Have an electrician install and service This 115 VAC is also available in the 14-pin connec- this equipment.
  • Page 21 TROUBLESHOOTING GUIDE Trouble Cause What To Do 1. Repair or replace. 1. Faulty input contactor (CR1). Input contactor (CR1 chatters). 2. Low line voltage. 2. Check input power. 1. Replace if blown - look for reason 1. Supply line fuse blown. Machine input contactor does not first.
  • Page 22 Trouble Cause What To Do Machine has low output and no con- 1. Output Control “Local-Remote” 1. Check position of switch. trol. switch (S2) in wrong position. 2. Output Control switch faulty. 2. Check switch and replace if faulty. 3. Open in feedback circuitry. 3.
  • Page 23 Trouble Cause What To Do Output control not functioning on 1. Output Control switch in wrong 1. Place switch in “Remote”. “Remote” control. position. 2. Faulty Output Control switch. 2. Check and replace if found faulty. 3. Faulty remote control poten- 3.

  • Page 24: Procedure For Replacing Pc Boards

    Procedure for Replacing PC Boards CHECKING SNUBBER PC BOARD WARNING In case of an SCR malfunction or failure, the Snubber ELECTRIC SHOCK PC Board should be checked. Turn the machine off can kill. and remove the sides of the machine. Board is mount- •...
  • Page 25 REMOTE CONTROL CHECK resistance in both directions. An open diode will have an infinite or high resistance in both direc- Disconnect the remote output control and connect an tions and a good diode will have a low resistance ohmmeter across 75 and 76 and rotate the rheostat in in Step b.
  • Page 26 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 – –...

  • Page 27: Wiring Diagrams

    WIRING DIAGRAM FOR CODES 10084 thru 10084, 11354, 11835 – –...

  • Page 28: Wiring Diagrams

    WIRING DIAGRAM FOR CODES 10087, 11087, 11088, 11089, 11055, 11836 CV-400 WIRING DIAGRAM L9270 L9270 – –...
  • Page 29 NOTES CV400...
  • Page 30 NOTES CV400...
  • Page 31 P-236 P-236 RETURN TO MAIN INDEX PARTS LIST FOR CV400 & CV500-I CV-400 & CV-500-I...
  • Page 32 P-236-A P-236-A ILLUSTRATION OF SUB-ASSEMBLIES 08-05-2011 CV-400 & CV-500-I...
  • Page 33 RETURN TO MAIN INDEX P-236-A.1 P-236-A.1 CV400 & CV500-I For Codes: 10084 to 11837 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 34 RETURN TO MAIN INDEX P-236-A.2 P-236-A.2 CV400 & CV500-I For Codes: 10084 to 11837 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 35 RETURN TO MAIN INDEX P-236-A.3 P-236-A.3 CV400 & CV500-I For Codes: 10084 to 11837 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 36 RETURN TO MAIN INDEX P-236-A.4 P-236-A.4 CV400 & CV500-I For Codes: 10084 to 11837 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 37 P-236-B.1 P-236-B.1 OPTIONAL EQUIPMENT LISTING Miscellaneous Options Available for your machine are listed below: # Indicates a change this printing. DESCRIPTION ...............PART NUMBER Remote Output Control .
  • Page 38 MISCELLANEOUS ITEMS P-236-B.2 P-236-B.2 (THESE ITEMS ARE NOT ILLUSTRATED) # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 DESCRIPTION PART NO.
  • Page 39 NOTES CV-400 & CV-500-I...
  • Page 40 P-236-C P-236-C Case Front Assembly 14A 14B 14B14C Part of 6A Part of 6A Part of 7A Part of 7A 08-05-2011 CV-400 & CV-500-I...
  • Page 41 P-236-C.1 P-236-C.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 42 P-236-D P-236-D Input Box & Fan Assembly Part of 10A Part of 10A Part of 10A Part of 10A Welded to Box Welded to Box 08-05-2011 CV-400 & CV-500-I...
  • Page 43 P-236-D.1 P-236-D.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 44 P-236-D.2 P-236-D.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 45 P-236-D.3 P-236-D.3 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 46 P-236-E P-236-E Base & Lift Bale Assembly 08-05-2011 CV-400 & CV-500-I...
  • Page 47 P-236-E.1 P-236-E.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 48 P-236-F P-236-F Transformer Assembly 08-05-2011 CV-400 & CV-500-I...
  • Page 49 P-236-F.1 P-236-F.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 50 P-236-G P-236-G Rectifier Bridge Assembly Part of 10A Part of 10A Part of 10A Part of 10A 12B 12C 12C12D 9B 9C 9C 9D 11A 11B 17B 15F 15G 15C Part of Base Part of Base 08-05-2011 CV-400 & CV-500-I...
  • Page 51 P-236-G.1 P-236-G.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 52 P-236-G.2 P-236-G.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 53 NOTES CV-400 & CV-500-I...
  • Page 54 P-236-H P-236-H Control Box Cover Assembly Part of 13A Part of 13A 15 Part of 8 Part of 8 9 9 10 Part of 4 Part of 4 11C 4 4 08-05-2011 CV-400 & CV-500-I...
  • Page 55 P-236-H.1 P-236-H.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 56 P-236-J P-236-J Covers 08-05-2011 CV-400 & CV-500-I...
  • Page 57 P-236-J.1 P-236-J.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 58 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 59 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 60 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.

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