Lincoln Electric CV 500-I, Operator'S Manual

Page 1: ...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 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 W...

Page 2: ...KER 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 avai...

Page 3: ...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 FUMES AND GASES can be dangerous 5 a Welding may produce f...

Page 4: ...gs 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...

Page 5: ...iés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloi...

Page 6: ...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 WEB SITE at www linc...

Page 7: ...ing 16 Input Power Connections 16 Output Cable Connections 17 Installation of Field Installed Options 17 18 Installation of Equipment Required for Recommended Processes 18 Operating Instructions 19 Safety Precautions 19 Power Source Operation 19 21 Duty Cycle 19 Starting the Machine 19 Control Settings Descriptions 19 21 Maintenance 21 Routine Maintenance 21 Troubleshooting 22 25 Procedure for Rep...

Page 8: ... of the various components Below are the symbols used 8 V V Input Power On Off Output Voltage Control Export Model Increase Decrease of Output Voltage OUTPUT CONTROL DIAL POWER ON OFF SWITCH U U Output Voltage Control European Model Remote Output Voltage Control Local Output Voltage Control OUTPUT CONTROL LOCAL REMOTE SWITCH ...

Page 9: ... 9 Circuit Breaker CIRCUIT BREAKER High Temperature THERMAL PROTECTION LIGHT Voltmeter VOLTMETER SWITCH Positive Electrode Negative Electrode ...

Page 10: ...onments with increased hazard of electric shock European model only Flux Cored Arc Welding Degree of protection provided by the enclosure 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 NEMA EW 1 IEC 974 1 S ...

Page 11: ... 11 Warning Identification WARNING IDENTIFICATION Signifying the Earth Ground Connection EARTH GROUND CONNECTION Signifying the Chassis Ground Connection CHASSIS GROUND CONNECTION ...

Page 12: ...rmance is achieved with a fixed pinch setting optimized for the most popular arc characteris tics OUTPUT VOLTAGE CONTROL The OUTPUT voltage control a small 2 watt poten tiometer is calibrated from 1 to 10 MACHINE OUTPUT CONTROL SWITCH LOCAL OR REMOTE The machine output voltage can be controlled by either the OUTPUT CONTROL on the machine con trol panel the output control on the wire feed unit or a...

Page 13: ...l circuit SOLID STATE OUTPUT CONTROL The output of the welder is electronically controlled by SCR s instead of mechanical contactors providing extra long life for highly repetitive welding applica tions SOLID STATE CONTROL SYSTEM The Control PC Board is located behind the control panel which hinges down for easy access to the board The Snubber PC Board is mounted on the back of the case front MACH...

Page 14: ...cuit If the machine is overloaded the primary thermostat will open the output will be zero and the thermal protection light will be on the fan will continue to run The secondary thermostat will open either with an excessive overload or insufficient cooling The out put will be zero and the protection light will be on the fan will continue to run When the thermostats reset the protection light will ...

Page 15: ...ter Circuit Suitable Undercarriages Remote output Control Other Features Net Weight Dimension Print Wiring Diagram Standards Compliance Operating Temperature CV 500 I K1347 50 60 Hz DC 500 450 400 40 38 36 39 36 5 34 50 60 100 60A 12V 500A 42V 46 220 440 220 380 440 230 460 Yes 45A 400A 34V 380V 50 Hz 29 6 400A 34V 50 Hz 65 400A 34V 50 Hz 70 400A 34V 50 Hz 3 2A 380V 50 Hz 1 0 KW 50 Hz Yes Standard...

Page 16: ...ver See Installation Data below 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 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 awa...

Page 17: ... behind the control panel on the front of the power source This control will give the same control as the output control on the machine REMOTE CONTROL ADAPTER CABLE K864 A V cable 12 30m long to connect a K857 Remote Control 6 pin connector with a wire feeder 14 pin connector and the machine 14 pin connec tor If a remote control is used alone the wire feeder connection is then not used CAPACITOR D...

Page 18: ... strip connectors The control cable from the wire feeding equipment is connected to the terminal strips behind the control panel A strain relief box connector is provided for access into the terminal strip section A chassis ground screw is also provided below the terminal strip marked with the symbol for connecting the auto matic equipment grounding wire See the appropriate connection diagram for ...

Page 19: ...ut control dial at the right of the control panel is a continuous control of the machine output voltage The control may be rotated between minimum and maximum to adjust the machine output even while welding The machine is equipped with line voltage compensa tion as a standard feature This will hold the output constant except at maximum output of the machine through a fluctuation of 10 input line v...

Page 20: ...VAC and 42 VAC AUXILIARY POWER AND CONTROL CONNECTIONS 14 Pin Connector The 14 pin connector receptacle type MS 3102A 20 27SX supplies auxiliary power 42 VAC is available at receptacle pins I and K A 10 amp circuit breaker protects this circuit 115 VAC is available at receptacle pins A and J except on the European model A 10 amp circuit breaker protects this circuit Note that the 42 VAC and 115 VA...

Page 21: ...st overloads on the SCR bridge assembly through the solid state fault protection circuit This circuit senses an overload on the power source and limits the output to approxi mately 550 amps by phasing back the SCR s Protection is provided to protect the circuitry from accidental grounds If leads 75 76 or 77 are acciden tally grounded to the positive output lead the output will be reduced to a low ...

Page 22: ...ts the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Se...

Page 23: ...or replace 2 Check input power 1 Replace if blown look for reason first 2 Check control transformer T2 and associated leads 3 Check input voltage at contactor 4 Check voltage against instruc tions 5 Replace coil 6 Replace switch 1 Make sure trigger circuit is being closed 2 Repair connection 3 Repair 4 Replace See Procedure for Replacing PC Boards 5 Amber thermal protection light is on Check for o...

Page 24: ...h S2 in wrong position 2 Faulty Output Control switch 3 Faulty Output Control potentiometer 4 Leads or connections open in control circuit 5 Faulty Control PC Board 1 Check position of switch 2 Check switch and replace if faulty 3 Check wiring and control PC Board wiring harness plugs 4 Replace See Procedure for Replacing PC Boards 5 Check and replace potentiometer if faulty Check wiring of Lead 7...

Page 25: ...r is raised or blown out 1 Place switch in Remote 2 Check and replace if found faulty 3 Check and replace if found faulty 4 Check all leads and connections internal or remote for continuity repair if necessary 5 Replace See Procedure for Replacing PC Boards 1 Work connection must be ade quate for application 2 Adjust procedures for improved starting 3 Replace See Procedure for Replacing PC Boards ...

Page 26: ... 550 amps if a short or overload is applied to the machine CHECKING SNUBBER PC BOARD In case of an SCR malfunction or failure the Snubber PC Board should be checked Turn the machine off and remove the sides of the machine Board is mount ed on back of the case front 1 Visually inspect the Board for overheated compo nents or damaged components CHECKING OUTPUT CONTROL RHEOSTAT ON MACHINE Turn machine...

Page 27: ... 2 and 3 2 Power Diode Test a Establish the polarity of the ohmmeter leads and set to X10 scale b Connect the ohmmeter positive lead to anode and negative lead to the cathode c Reverse the leads of the ohmmeter from Step b d A shorted diode will indicate zero or an equally low resistance in both directions An open diode will have an infinite or high resistance in both direc tions and a good diode ...

Page 28: ... 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 h a v e g r o o v e s a t t h e c a b l e e n d S o a p o r o t h e r n o n p e t r o l e u m d i a m e t e r o f c a b l e N O T E S o m e b o o t s a r e d e s i g n e d t o a c c o m m o d a t e S 1 8 7 3 7 9 2 0 9 1 J T U R N T H E P O W E R S W I T C H O F T H E W E L D I N G P O W E R S O U R C E O F F B E F O R E I...

Page 29: ... to Control P C board To T1 main transformer To plug P1 To side of capacitor bank _ X1 X2 X3 GATE _ POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD SHUNT P5 221 222 223 204 220 204 204 204 220 D1 D2 D3 SCR1 SCR2 SCR3 G1 G2 G3 D4 ANODE CATHODE ANODE CATHODE P3 Gate leads plug to Control P C board To T1 main transformer To plug P1 To side of capacitor bank _ X1 X2 X3 GATE _ 29 ...

Page 30: ...accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 31: ...NOTES ...

Page 32: ...NOTES ...

Page 33: ... electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 34: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 35: ...s 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 World s Leader in Welding and Cutting Products ...