Lincoln Electric IDEALARC CV-305 Service Manual
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Lincoln Electric IDEALARC CV-305 Service Manual

Lincoln Electric IDEALARC CV-305 Service Manual

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IDEALARC
CV-305
®
For use with machines having Code Numbers:
11177 thru 11179
SERVICE MANUAL
SVM191-A
| Issue D ate 09-Apr
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

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  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. IDEALARC CV-305 ® For use with machines having Code Numbers: 11177 thru 11179 SERVICE MANUAL SVM191-A | Issue D ate 09-Apr ©...
  • Page 2 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 ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area. process used and properly operating If this is not possible, cover them to prevent regulators designed for the gas and welding...
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-iv Installation .
  • Page 7 TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 8 INSTALLATION TECHNICAL SPECIFICATIONS – IDEALARC CV-305 INPUT - THREE PHASE ONLY Voltage, 60Hz Current at Rated Output, Code 100% Duty Cycle Number 208/230/460 Volts 51/48/24 Amps 11177 230/460/575 Volts 48/24/20 Amps 11178 RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 100% Duty Cycle 32.6...
  • Page 9 The frame of the welder must be grounded. A ground terminal marked with the symbol located on the • Always connect the Idealarc CV-305 grounding terminal (located on the welder base near the reconnect panel) to a base of the machine is provided for this purpose. See...
  • Page 10 INSTALLATION FIELD INSTALLED OPTIONS LN-742 to CV-305 (see the ACCESSORIES section of this manual and a) Turn the CV-305 Power switch to the "OFF" posi- For installation of compatible field installed options tion. refer to the instructions included with those options. b) Connect the LN-742 control cable to the wire feed- er receptacle on the CV-305.
  • Page 11 INSTALLATION PARALLELING The CV-305 is not designed to be paralleled with another C-305 or 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 recep- tacle.
  • Page 12 NOTES IDEALARC® CV-305...

  • Page 13: Table Of Contents

    TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Precautions .

  • Page 14: Operation

    OPERATION SAFETY PRECAUTIONS Read this entire section of operating instructions before operating the machine. WARNING ELECTRIC SHOCK can kill. • Unless using cold feed feature, when feeding with gun trigger, the electrode and drive mechanism are always electrically energized and could remain energized several seconds after the welding ceases.
  • Page 15 OPERATION GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL SMAW INPUT POWER GMAW FCAW HIGH TEMPERATURE GTAW OPEN CIRCUIT VOLT- MACHINE STATUS CIRCUIT BREAKER INPUT VOLTAGE WIRE FEEDER OUTPUT VOLTAGE POSITIVE OUTPUT INPUT CURRENT NEGATIVE OUTPUT OUTPUT CURRENT PROTECTIVE 3 PHASE INVERTER GROUND...

  • Page 16: General Description

    OPERATION • 115 VAC, 5 amp auxiliary power available for the wire CAUTION feeder; circuit breaker protected. • Magnum Twist-Mate™ output receptacles. When using a CV-305 power source with wire feeders, there will be a small spark if the electrode contacts the •...
  • Page 17 OPERATION CONTROLS AND OUTPUT SETTINGS All operator controls and adjustments are located on the case front of the CV-305. Refer to Figure B.1. FIGURE B.1 - CONTROL AND OUTPUT PANEL 1. POWER SWITCH NOTE: Due to voltage drops in the welding cables and at cable connection points, the actual arc A two-position toggle switch.Controls the input voltage may be lower than that displayed on...
  • Page 18 OPERATION 9. WIRE FEEDER VOLTMETER SWITCH 12. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION. This switch selects the polarity of the WORK sens- The High Inductance Output connec- ing lead (#21) to the wire feeder. When welding tor is a Magnum Twist-Mate™, recep- electrode positive, (MIG, Outershield and some tacle.

  • Page 19: Starting The Machine

    OPERATION STARTING THE MACHINE AUXILIARY POWER The power switch at the extreme right side of the con- 42 volt AC auxiliary power, as required for some wire trol panel energizes the CV-305. feeders, is available through the wire feeder recepta- cle.
  • Page 20 NOTES IDEALARC® CV-305...
  • Page 21 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Factory Installed Equipment .
  • Page 22 ACCESSORIES FACTORY INSTALLED COMPATIBLE LINCOLN EQUIPMENT OPTIONS/ACCESSORIES The CV-305 is intended for use with the LF-72, LN-7, LN-742, and LN-25 wire feed units. Use the Cables / There are no factory installed options/accessories on Kits listed below to make connection easily: the CV-305.
  • Page 23 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .
  • Page 24 MAINTENANCE SAFETY PRECAUTIONS MACHINE AND CIRCUIT PROTECTION WARNING The CV-305 Control PC Board has built-in diagnostic routines to alert the operator when trouble exists. ELECTRIC SHOCK can kill. When a trouble condition occurs, the CV-305 meter will refers to a specific error. See TROUBLESHOOTING display an error code, in the form "EXX", where "XX"...
  • Page 25 MAINTENANCE FIGURE D.1. - Major Component Location 1. Casefront 2. Cover Assembly 3. Center & Base Assembly 4. Capacitor Bank Assembly 5. Case Back Assembly 6. Fan, Terminal Board & Choke Assembly IDEALARC® CV-305...
  • Page 26 NOTES IDEALARC® CV-305...
  • Page 27 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Input Line Voltage, Line Switch &...
  • Page 28 THEORY OF OPERATION FIGURE E.2 — Input Line Voltage, Line Switch and Main Transformer OUTPUT CONTROL METER 14 PIN AMPHENOL TRIGGER AND REMOTE 12VAC CONTROL BOARD MOTOR 115VAC 12VAC INPUT RECONNECT LINE PANEL SWITCH SHUNT OUTPUT TERMINALS CAPACITORS CHOKE OUTPUT MAIN RECTIFIER TRANSFORMER...
  • Page 29 THEORY OF OPERATION FIGURE E.3 — Output Rectification, Filtering, Control Feedback, & Power Factor Enhancement OUTPUT CONTROL METER 14 PIN AMPHENOL TRIGGER AND REMOTE 12VAC CONTROL BOARD MOTOR 115VAC 12VAC INPUT RECONNECT LINE PANEL SWITCH SHUNT OUTPUT TERMINALS CAPACITORS CHOKE OUTPUT MAIN RECTIFIER...
  • Page 30 THEORY OF OPERATION A thermostat protects the CV-305 from excessive oper- ating temperatures. Excessive operating temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostat will open and deactivate the machine’s out- put.
  • Page 31 THEORY OF OPERATION Figure E.4 - SCR Operation INPUT CATHODE OUTPUT NOTE: AS THE GATE PULSE IS APPLIED ANODE LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED. GATE A silicon controlled rectifier (SCR) is a three terminal An SCR is fired by a short burst of current into the gate. device used to control rather large currents to a load.
  • Page 32 NOTES IDEALARC® CV-305...
  • Page 33 TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR Troubleshooting and Repair ............. . .F-1 How to Use Troubleshooting Guide .

  • Page 34: How To Use Troubleshooting Guide

    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 35: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 36 5. The control board may be faulty. Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 37 6. The control board may be faulty. Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 38 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 39 5. The control board may be faulty. Replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 40 2. If an error message is displayed Replace. Messages. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 41 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 the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 42 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...

  • Page 43: Troubleshooting Guide

    219), or voltage feedback (leads 213B, 214B, and 224B). CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC® CV-305...
  • Page 44 F-12 NOTES F-12 IDEALARC® CV-305...

  • Page 45: Main Transformer Test

    MAIN TRANSFORMER TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 46 MAIN TRANSFORMER TEST PROCEDURE (CONTINUED) F-14 TROUBLESHOOTING & REPAIR F-14 TEST PROCEDURE WARNING 10. Test for 115 VAC between lead #33 at circuit breaker and pin "J" (lead #31) on the amphenol The ON/OFF POWER SWITCH will be "hot" during connector.
  • Page 47 MAIN TRANSFORMER TEST PROCEDURE (CONTINUED) F-15 TROUBLESHOOTING & REPAIR F-15 11. Locate lead #42A connected to circuit breaker CB1 13. Locate the following leads connected to output rec- and pin "I" on the 14 pin amphenol connector on tifier bridge: #221, #222, and #223. See Figure the Case Front.
  • Page 48 F-16 NOTES F-16 IDEALARC® CV-305...
  • Page 49 STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 50: Control Pc Board

    STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE (CONTINUED) F-18 TROUBLESHOOTING & REPAIR F-18 TEST PROCEDURE FIGURE F.4 - PC BOARD LOCATION 1. Disconnect main AC input power to the machine. 2. Locate and remove the following plugs: CONTROL BOARD METER Note: Location of plugs will vary depending on code. BOARD See Figure F.4.
  • Page 51 STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE (CONTINUED) F-19 TROUBLESHOOTING & REPAIR F-19 FIGURE F.6 - SCR TEST POINTS ANODE CATHODE strap. See Figure F.5. 6. Disconnect the D4 diode pigtail from the positive b. Reverse the meter leads and measure the resistance from the cathode to anode of SCR1.
  • Page 52 STATIC OUTPUT RECTIFIER BRIDGE TEST PROCEDURE (CONTINUED) F-20 TROUBLESHOOTING & REPAIR F-20 10. Test diode D1 for proper operation. 11. Test Diodes D2, D3, D4 & D5 for proper operation using the same procedure described in Step 10. a. Measure the resistance of diode D1 from the anode (+ probe) to the cathode (- probe) using NOTE: Diodes D1, D2 &...
  • Page 53 CHOKE TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 54 CHOKE TEST PROCEDURE (CONTINUED) F-22 TROUBLESHOOTING & REPAIR F-22 FIGURE F.8 - CHOKE CHOKE PROCEDURE 1. Using a digital ohmmeter, make sure that the choke windings are not grounded to the lamina- tion (> 1megohm). No windings or terminal connections should look burned or over-heated.
  • Page 55 P.F.C. (LI) COIL TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 56 P.F.C. (LI) COIL TEST PROCEDURE (CONTINUED) F-24 TROUBLESHOOTING & REPAIR F-24 FIGURE F.9 - CHOKE CHOKE PROCEDURE 1. Using a digital ohmmeter, make sure that the choke windings are not grounded to the lamina- tion (> 1megohm). No windings or terminal connections should look burned or over-heated.

  • Page 57: Output Rectifier Bridge

    ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 58 ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE (CONTINUED) F-26 TROUBLESHOOTING & REPAIR F-26 TEST PROCEDURE FIGURE F.10 -. PC BOARD LOCATION 1. Disconnect main AC input power to the machine. 2. Locate and remove the following plug. See Figure F.10. CONTROL BOARD METER PLUG #...
  • Page 59 ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE (CONTINUED) F-27 TROUBLESHOOTING & REPAIR F-27 7. Remove the red insulating paint from the heat sink FIGURE F.12 test points. See Figure F.12. NOTE: DO NOT DISASSEMBLE THE SCR RECTIFI- ER HEAT SINK ASSEMBLY. 8.
  • Page 60 ACTIVE SCR RECTIFIER ASSEMBLY TEST PROCEDURE (CONTINUED) F-28 TROUBLESHOOTING & REPAIR F-28 10. Close switch SW-1. 14. Open switch SW-1. 15. Reconnect the Tester leads. See Figure F.16. NOTE: Switch SW-2 should be open. 11. Read meter for zero voltage. a.
  • Page 61 F-29 TROUBLESHOOTING & REPAIR F-29 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM NO LOAD - OUTPUT CONTROL AT MAXIMUM 0 Volts SCOPE SETTINGS This is a typical output voltage generated from a properly operating machine. Note Volts/Div ....20 V/Div. that each vertical division represents 20 volts and that each horizontal division repre- Horizontal Sweep...
  • Page 62 F-30 TROUBLESHOOTING & REPAIR F-30 TYPICAL DC WELD OUTPUT - MACHINE LOADED 0 Volts MACHINE LOADED TO 300 AMPS AT 32 VDC SCOPE SETTINGS This is a typical CV output voltage generat- ed from a properly operating machine. Note Volts/Div ....20 V/Div. that each vertical division represents 20 volts and that each horizontal division repre- Horizontal Sweep...
  • Page 63 F-31 TROUBLESHOOTING & REPAIR F-31 ABNORMAL OUTPUT WELD VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING 0 Volts MACHINE LOADED TO 300 AMPS AT 32 VDC SCOPE SETTINGS This is not a typical CV output voltage wave- form. Note the “ripple”...
  • Page 64 F-32 TROUBLESHOOTING & REPAIR F-32 ABNORMAL OUTPUT WELD VOLTAGE WAVEFORM - MACHINE LOADED CAPACITOR BANK NOT FUNCTIONING 0 Volts MACHINE LOADED TO 300 AMPS AT 15 VDC SCOPE SETTINGS This is NOT the typical output voltage wave- form. Note the increased “ripple” in the out- Volts/Div .
  • Page 65 F-33 TROUBLESHOOTING & REPAIR F-33 ABNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM NO LOAD - CAPACITOR BANK NOT FUNCTIONING 0 Volts SCOPE SETTINGS This is not the typical output voltage wave- form. The output capacitors were discon- Volts/Div ....20 V/Div. nected to simulate a faulty capacitor bank.
  • Page 66 F-34 TROUBLESHOOTING & REPAIR F-34 TYPICAL SCR GATE VOLTAGE WAVEFORM 0 Volts SCOPE SETTINGS This is the typical SCR gate pulse voltage waveform. The machine was in an open cir- Volts/Div ....1 V/Div. cuit condition (no load) and operating prop- erly.
  • Page 67 CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 68 F-36 TROUBLESHOOTING & REPAIR F-36 (CONTINUED) CONTROL PC BOARD REMOVAL AND REPLACEMENT PROCEDURE PROCEDURE 1. Disconnect main AC input power to the machine. 2. Remove the Case Roof. 3. Disconnect the Molex plugs from the control board. 4. Remove the four screws located on the outboard side of the Case Front panel that mount the control board to the front panel.
  • Page 69 CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 70 F-38 TROUBLESHOOTING & REPAIR F-38 (CONTINUED) CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE PROCEDURE 1. Disconnect main AC input power to the machine. 2. Test that the capacitors are discharged using a D.C. voltmeter. Polarity must be observed. bank assembly: See Table F.1. See Figure F. 14. 3.
  • Page 71 F-39 TROUBLESHOOTING & REPAIR F-39 (CONTINUED) CAPACITOR BANK REMOVAL AND REPLACEMENT PROCEDURE FIGURE F.14 - CAPACITOR BANK REMOVAL Positive lead to Shunt Power Factor Choke Lead Capacitor Bank Copper Strap Positive Heat Sink The Bus Bar where the D1, D2 and D3 pigtails are normally connected is not shown for clarity. IDEALARC®...
  • Page 72 F-40 NOTES F-40 IDEALARC® CV-305...
  • Page 73 OUTPUT RECTIFIER BRIDGE REMOVAL & REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 74 OUTPUT RECTIFIER BRIDGE REMOVAL & REPLACEMENT (CONTINUED) F-42 TROUBLESHOOTING & REPAIR F-42 PROCEDURE 7. Cut any cable ties that would restrict the removal of 1. Disconnect main AC input power to the machine. the assembly. 2. Remove the Case Roof and Case Sides. 8.
  • Page 75 PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 76 F-44 TROUBLESHOOTING & REPAIR F-44 PROCEDURE (CONTINUED) MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS PROCEDURE DIODE STUD FOOT- INCH- SIZE POUNDS POUNDS 1. Loosen the appropriate diode nut and remove the diode that is to be replaced. 3/4 - 16 25-27 300-324 3/8 - 24...
  • Page 77 SCR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 78 SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) F-46 TROUBLESHOOTING & REPAIR F-46 PROCEDURE: 3. Clean the area on the heat sink around the SCR mounting surface. Using a putty knife, or similar tool. DO NOT SCRATCH THE SCR MOUNTING Note: Before disassembling the existing rectifier, note SURFACE.
  • Page 79 SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) F-47 TROUBLESHOOTING & REPAIR F-47 8. Go to procedure that matches cap screws. NOTE 3. Insert bolts and leaf spring into the plastic housing. WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PROCEEDING TO THE ASSEMBLY 4.
  • Page 80 SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) F-48 TROUBLESHOOTING & REPAIR F-48 CLAMPING PROCEDURE FOR 1/4-28 CLAMPING PROCEDURE FOR 1/4-20 BOLTS. BOLTS. Note: This procedure can only be used with 1/4-28 Note: This procedure can only be used with 1/4-20 bolts. bolts.
  • Page 81 SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) F-49 TROUBLESHOOTING & REPAIR F-49 PROCEDURE FOR THE 5/8 INCH WIDE SPRING Figure F.20 - Clamp Assembly. 1. Place a piece of sleeving around each bolt. 2. Insert bolts thru the leaf spring. The leaf spring is flat so the orientation of the leaf spring does not SLEEVING matter.
  • Page 82 SCR REMOVAL AND REPLACEMENT PROCEDURE (CONTINUED) F-50 TROUBLESHOOTING & REPAIR F-50 PROCEDURE FOR CLAMPING 1/4-28 CLAMPING PROCEDURE FOR 1/4-20 BOLTS. BOLTS. Note: This procedure can only be used with 1/4-28 Note: This procedure can only be used with 1/4-20 bolts. bolts.
  • Page 83 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 84 FAN MOTOR AND FAN REMOVAL AND REPLACEMENT (CONTINUED) F-52 TROUBLESHOOTING & REPAIR F-52 PROCEDURE 6. Remove that Case Back Panel. 1. Disconnect main AC input power to the machine. 2. Remove the Case Roof and Sides. 7. Label and cut the fan motor leads. 4.
  • Page 85 CENTER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 86 F-54 TROUBLESHOOTING & REPAIR F-54 (CONTINUED) CENTER ASSEMBLY REMOVAL AND REPLACEMENT PROCEDURE ROCEDURE 9. Label and cut the fan motor leads and clear leads for easy removal. 1. Disconnect main AC input power input leads to the 10. Remove the four screws attaching the reconnect machine.
  • Page 87 F-55 TROUBLESHOOTING & REPAIR F-55 RETEST AFTER REPAIR Should a machine require the removal of any mechanical part that could affect the machine’s electrical character- istics, or if any electrical components are repaired or replaced, that machine must be retested. INPUT IDLE AMPS AND WATTS Input Volts/Hertz Maximum Idle Amps...
  • Page 88 F-56 NOTES F-56 IDEALARC® CV-305...
  • Page 89 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram Codes 11177, 11178 - (L12393) .
  • Page 90 ELECTRICAL DIAGRAMS WIRING DIAGRAM - CV-305 - CODES 11177 & 11178 - L12393 WIRING DIAGRAM CV-305 (60Hz) SNUBBER/BYPASS P.C. BOARD 204C SCR3 INPUT SUPPLY RECONNECT 204D PANEL LINES 7.5 OHM .05uf 320VAC 220 W 600V 400 A. 50mV SHUNT 224A SCR2 213B N.B.
  • Page 91 ELECTRICAL DIAGRAMS WIRING DIAGRAM - CV-305 CODE 11179 - L12394 WIRING DIAGRAM CV 400-I (EXPORT 50/60 Hz) RECONNECT SNUBBER/BYPASS PANEL P.C. BOARD 204C INPUT SUPPLY LINES SCR3 .05uf 204D 320VAC 600V 7.5 OHM 220 W 400 A. 50mV 213B SHUNT 224A N.B.
  • Page 92 ELECTRICAL DIAGRAMS SCHEMATIC -CONTROL PC BOARD - ALL CODES - G4337-1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. IDEALARC® CV-305...
  • Page 93 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 94 ELECTRICAL DIAGRAMS SCHEMATIC - METER PC BOARD - M15892 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. IDEALARC® CV-305...
  • Page 95 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 96 ELECTRICAL DIAGRAMS SCHEMATIC - SNUBBER PC BOARD - S19687 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. IDEALARC® CV-305...
  • Page 97 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.

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