Lincoln Electric IDEALARC CV-305 User's Manual
Contents
1. Section F Parts Mariual cu d eua aon rv na x So d E uU dee P511 A 1 INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC CV 305 INPUT THREE PHASE ONLY Voltage 60Hz 208 230 460 Volts 230 460 575 Volts Duty Cycle 10096 Duty Cycle NEMA Class 100 Welding Current Voltage Range Continuous 50A 7V 400A 37V DC Efficiency at 100 Load 75 Idle Power 950W Height 21 5 in Lift bail add 3 12 in 546 mm Lift bail add 83 mm Current at Rated Output 100 Duty Cycle 51 48 24 Amps 48 24 20 Amps RATED OUTPUT Amps 315 OUTPUT Open Circuit Voltage 10 50 MISC INFORMATION Power Factor at 100 Load Ka PHYSICAL DIMENSIONS CV 305 LINCOLN 5 A 1 Code Number 11177 Volts at Rated Amperes 32 6 Auxiliary Power 42 Volts AC 10 Amps 115 Volts AC 5 Amps Both Circuit Breaker Protected Idle Current 575Volts input 3Amps 460Volts input 3 4Amps 230Volts input 7Amps 208Volts input 8Amps Weight 330 Ibs 150 kg A 2 Read entire installation section before starting installation SAFETY PRECAUTIONS A WARNING _ ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the discon nect switch or fuse box before working on this equipment Turn the Power switch on the CV 305 OFF before co2. HOLIMS 15 E 5 EN fy TaNVd Y 193NNOO3H saN ATddNS zH09 S0 A9 Weld ONIMIM CV 305 LINCOLN E F 2 299005 394N0S YAMOd AHL 40 TON3HdNV Nid vL SHL OL H31d VOV 1081 09 0 2 POPON JLOWSY 798 V JO NOILVTIVLSNI SAYINDAY 1OH LNOO SLOWSY 2987 30 SSN H3MOd ALiavTOd 39NVHO OL SAILISOd 300810313 SMOHS ON NOILVOMdd 40 FTOAO ALN ANY 9371 38 LSNW 318VO ONIGTAM 3199 390819313 OL A IOC 318VO LAdNI 01 818 LM dJldVQVv IOHLNOO H3Q0334 JLOWSY 7987 IVNOILdO DIAGRAMS CV POWER SOURCE TO AN LN 7 AND K857 F 2 TOULNOO 310 N3H 1987 IWNOILdO TONSHdNY Nid vt TIN NVO QUIYOBW SIU 9995 X90HS 10 asn pjnous suosied Daer un e JT eu 910198 gen 941 1e uos 1oeuuoosip eu 921 08 Bund Bulpjan eui 0 19 indui e MN Y 39810 d3MOd I AO AD CV 305 LINCOLN E DIAGRAMS F 3 CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER F 3 SANIHOWW NO 1N3S3Hd LON JN INQINIXVIN TYNNYN NOLLONYLSNI IN ih 3 SQv3138010 OL AY BH lt l Log 91 NOLLV31OSI ASN ONIGTAM 1VNBIS v NYNLSY LVHL S430334 ON ATIVAG
3. Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 5 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat spark
4. or Nid OL Nid 8 Nid9 0 9 8 ag 97 v t Doopro ad 5 Fal LE zt 9 40 2015 LNANOdWOO JONANDAS NIYIANWNN ALIAVO HOLO3NNOO 2913 H3d S 11O8WAS 1VOIH 103 T3 NOILISOd SLTOA NI NMOHS SdWV SLIOA EUR 0 xr tes S e sb 60 2 p 80 LE 202 lt lt 9 v 9 L T 922 Sle lt 9 OHLNOO YALSWLIOA 30333 34M Tu oO OD za JOS HOLIMS HALINLIOA Y30334 S DIAGRAMS 1 1 0 NIVIA VLE NOHID ini Jequunu epoo 1ueuudinbe ap jueunjedeg eui sjeued euo eui episui pejsed si epoo sejnomed Jenueui siy Aq 10 eq jou JO 5 SIUL LON HOLIMS 15 OL c L HOLIMS 8017 L HOLIMS 150 EJ 22 Add NI H IS 9 AAA 1 6 9 5 1 D 9 E ASLS DN L93NNO934 DN
5. Be sure the CV 305 is properly installed and that all accessories are properly hooked up before attempting operation DUTY CYCLE 315 Amps 32 6 Volts at 10096 Duty Cycle is based on operation for a 10 minute period CV 305 LINCOLN B 4 1 2 3 4 5 OPERATION CONTROLS AND OUTPUT SETTINGS All operator controls and adjustments are located on the case front of the CV 305 Refer to Figures B 1 FIGURE B 1 CONTROL AND OUTPUT PANEL POWER SWITCH A two position toggle switch Controls the input power to the CV 305 VOLTAGE ADJUST Controls the CV 305 output voltage THERMAL PROTECTION INDICATION LIGHT Indicates that the protection thermostat has activated The digital meter will display E10 when this occurs When the light turns off the machine will be capable of supplying welding out put power again NOTE Leaving the power switch in the ON posi tion will result in the most rapid cooling VOLTS AMPS SWITCH Selects either output current or arc voltage to be displayed on the digital meter DIGITAL VOLTMETER AMMETER Displays the CV 305 output current or the arc voltage CV 305 NOTE Due to voltage drops in the welding cables and at cable connection points the actual arc voltage may be lower than that displayed on the voltmeter Use weldin
6. aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc p
7. 193NNOO3H AE ES TANVd INOO3H Waxvauas VOL igo 29 0 0 92 vev Ke dOLIG Vi E 907 iVisomuani Soc ABVANO9I3S Loz 90119 3 D ooz VW 502 0124 AC 3 oz v NN pee uz avez de 94 gre lt 3LIHM 115 1 1 aay vs NOLLISOd 1V201 NI NMOHS HOLIMS 310W34 1V9071 IVAOZE 6Lz 4 a 9 1051409 202 Ir JIN3W3ONVHN3 30193 ELL d aviz 31IHM 612 mp F 1 avez SADVLIOA SZS 09v 0 c HOLIMS 15 OL HOLIMS LS OL c L HOLIMS 15 Pd LJ ajaja y ye 9 de H um n D DN L93NNO934 DN 103NNO03H otc JAANI TANVd INOO3H SHOVLIOA 09v 0 2 80c gt Le 1358 LNNHS 3 AUI0S V 007 od SSvdAg H3 V 2 e ezz 3009 1513195373 TVNOLLVN WALSAS VOL 8 voz
8. It is also capa ble of welding the flux cored wires The CV 305 is recommended for use with the LF 72 LN 7 LN 742 and LN 25 wire feeder models OPERATIONAL FEATURES AND CONTROLS Two inductance positions operator can choose the optimum output characteristics Solid State Output Contactor no noise no moving parts to wear Digital Voltmeter Ammeter is standard Power on off switch 42 VAC 10 amp auxiliary power available for the wire feeder Circuit breaker protected 115 VAC 5 amp auxiliary power available for the wire feeder circuit breaker protected Magnum Twist Mate output receptacles e Single MS type 14 pin connection for wire feeder Solid state controls with line voltage compensation Optional remote control capability DESIGN FEATURES Clean appearance and simple controls easy to operate Electronic and thermostatic protection from over loads Submersion dipping of assembled transformer choke and rectifier in special sealing insulating material gives extra protection against moisture and corrosive atmospheres Microprocessor based Control PC Board has built in diagnostic routines Compact size requires only 19 x 26 482mm x 660mm footprint Modular construction for easy servicing Recessed panels protect output studs and controls Large safety margins and protective circuits protect rectifiers from transient voltages and high currents POWER SOURCE OPERATION
9. as the K857 see INSTALLA TION section place the Local Remote switch see Figure B 1 in the Remote position The remote control now con trols the output voltage in the manner described above This control may be adjusted while welding to change the CV 305 output AUXILIARY POWER 42 volt AC auxiliary power as required for some wire feeders is available through the wire feeder recepta cle 10 amp circuit breaker protects the 42 volt cir cuit from overloads CV 305 machines can also supply 115 volt AC auxil iary power through the wire feeder receptacle A 5 amp circuit breaker protects the 115 volt circuit from overloads NOTE Do not use circuits 2 or 4 for control of auxil iary loads The 2 4 circuit is isolated from the 31 32 and 41 42 circuits CAUTION Note that some types of equipment especially pumps and large motors have starting currents which are significantly higher than their running current These higher starting currents may cause the circuit breaker to open If this situation occurs the user should refrain from using the CV 305 auxiliary power for that equip ment OVERLOAD PROTECTION This welder has thermostatic protection from exces sive duty cycles overloads loss of cooling and high ambient temperatures When the welder is subjected to an overload or loss of cooling a thermostat will open This condition will be indicated by the illumina tion of the yellow Thermostatic Protection Lig
10. d3ildVvQv 1OHINOO 31OIN3H 7987 TVNOILdO JON3HdNNV 3ounos YAMOd Nid v I AO AO TI QUIYOBW SIY 991 195 MOOHS 10 asn pinoys suosiad e au y 910198 997 aut 19 Yms joeuuoostp eu Buisn 9NINHVM Y 951106 18M04 34 0 amod UN e NOILO3NNOO NOILdO L t VM 92 1 OL 39unos I AD AD CV 305 LINCOLN E DIAGRAMS F 7 LINCOLN POWER SOURCE TO AN LN 742 F 7 607005 TTT wat NOHJ J18YO Nid Y L Mah ESE 3950 159490 41 74 9 743 CNV Sv v Q 6 9 5 OV 7M NOILISOd 310IN38 OL HOLIMS TOdLNOO 5 d3MOd 135 LIM SLOWSY 1 689 ONISN ON 31870 NO Q3193NNOO LON 38V ALSI LON SNid O N ALlav 1Od OL 394N0S d3MOd NO HOLIMS H313IAL 10A d30334 34IM 155 ANY 394N0S H3MOd LV 318VO 80M ANY 3008193 3Sd3A3d 4401 H3MOd Nun ALIaV TOd 39NVHO Ol 3AILLISOd 380819313 SMOHS WV ON NOILVONIddV 40 319A9 ANY 1IN344N9 09215 38 LSAW 318 VO SNIQTJ3M TIN 5 MOOHS SIY 901 98 31419713 10 asn je sul pinoys suosJed e eut eonog Dupau ay uo uoyws amod an 0 e 01 318v9 Nld vL M3IA INOHA 310v1d393H 13490S vL 9 73 d
11. 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists 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 Service Facility 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 305 LINCOLN 5 E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout thi
12. e X7TTLA UAVCRUD PRE ETBRAL FE DF I gt e His BIS ER Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e 200 wel WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO BIR Chinese lea oe lue chal Gall bacs ga d Jg iti Mall oe Quad by pha NM uu 0 ail e AREY cuts UI ai tha Y e Aale Cut Al dl LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SBM BHO X HD OHBRBEE lt K HA EL TRHOKRERE HAM ERU Rr de t D LR AMEN o 0 Al Soll SALAD HAY TAS PSP HHCH Saal dl aut elaia Jud al ply Gail ag ls Gras L LINCOLN World s Leader in Welding and Cutting Products e Sales and Service through Subsidiar
13. pins for corrosion contamination or looseness 2 Check leads in the plug harness for loose or intermittent connection b If PC board is visibly damaged electrically before possibly subjecting the new PC board to the same cause of failure check for possible shorts opens or grounds caused by 1 Frayed or pinched lead insulation 2 Poor lead termination such as a poor contact or a short to adjacent connection or surface 3 Shorted or open motor leads or other external leads 4 Foreign matter or interference behind the PC boards c If PC board is visibly damaged mechanically inspect for cause then remedy before installing a replacement PC board If there is damage to the PC board or if replacing PC board corrects problem return it to the local Lincoln Electric Field Service Shop PC BOARD TROUBLESHOOTING PROCEDURES CONTROL PC BOARD The Control PC Board controls all machine functions including the thermal protection indicator light and the Meter PC Board Most problems if not caused by faulty wiring machine misuse will stem from a faulty Control PC Board Perform the following diagnostic procedure before replacing the Control PC Board 1 Turn off the input power at the fuse box 2 Check for loose connections in the PC Board plugs particularly J3 3 Disconnect the J3 plug from the Control PC Board Measure the resistance between the following wire terminals in the plug A Between wire 20
14. reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Installation Section A Technical Specifications 1 Select Suitable LOCation iieri eicere ete intended eee A 2 Input Connections siens A 2 Field Installed Options ketenes ia said de eee A 3 Required Equipment Control Cable A 3 Output Connections niii icd n ire ne A 3 TECH Le MI A 4 Connection of Auxiliary Equipment to Wire Feeder Receptacle A 4 ier l Section B Safety Precautions iii B 1 Graphic Symbols EE B 2 General Description sisi B 3 Recommended Processes and Equipment B 3 Operational Features and Controls B 3 De SIQN B 3 Power Source Operation iii B 3 Duty CYCIS cs B 3 C
15. 0 and wire 201 B Between wire 202 and wire 203 Both of these resistances should be less than 1 ohm If these resistances are not less than 1 ohm check the wiring back to the main transformer If these voltages are less than 1 ohm refer to Procedure for Replacing PC Boards METER PC BOARD When the Meter PC Board malfunctions first determine if the rest of the machine functions correctly If so then the problem is in either the harness between the meter and control boards or in the meter board itself Refer to Procedure for Replacing PC Boards As a last resort the Control PC Board may have to be replaced 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 305 LINCOLN 5 ET TROUBLESHOOTING ES OUTPUT VOLTAGE The open circuit voltage of the machine should be 10 to 43 volts If any other condition exists refer to the Troubleshooting Guide FAULT PROTECTION OPERATION The overload protection circuit on the PC Board will cause the CV 305 meter to display E60 This pro tection circuit will reset itself automatically The short circuit protection circuit will cause the meter to display E00 The CV 305 power switch must be turned OFF and then ON to return the machine to normal output CHECKING SNUBBER CIRCUIT
16. 01 F 11 STAGOW 431143 NO NOILVHNOIANO9 ON SM3H9S 91 9 ONISN NMOG ONILNNOW 303 3SV8 S10 1S 8104 VN 92 00 009 z9 ez lu 0343139 827 9621 96 05 979 09 L2 DIAGRAMS DIMENSION PRINT gu LT x 7 LI 829 ERAN Oe Uc fe 029 ogzi 7 16 op 087 0861 66 06 667 99 61 208 66 LL 099 00 92 609 90 02 9901 89 7 F 11 CV 305 LINCOLN E WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o
17. 14 pin wire feeder recep tacle These circuits such as the auxiliary voltage contactor and remote control circuits may be accessed with a K867 Universal Adapter This adapter plugs into the receptacle and provides the user with short wire leads for connections Refer to the instructions provided with the K867 as well as the wiring diagram for the CV 305 power source for details on making those connections For your conve nience wire feeder connection details are shown in the DIAGRAM section NOTE If you intend to use a standard Lincoln wire feeder order the appropriate input cable for the specific feeder It will make all of the con trol and power connections between the CV 305 and the wire feeder WITHOUT the need for a K867 Universal Adapter CV 305 LINCOLN 5 B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before oper ating the machine GENERAL WARNINGS SAFETY PRECAUTIONS A WARNING cM e 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 dangerous AR Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS L can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles A
18. 19A9 ALN IN344N9 937 38 LSNW 318 VO ONIGTAM 318V9 30041931 OL ON H3033J fld GMT 7879 VNOILdO d3ldVQV IOHINO9 31O0IN3H 7987 IVNOLLdO ON 5 d3MOd JON3HdNV TOYULNOO 3410 38 28 WNOILdO TI NO eulu9eu 14 991 195 MOOHS 91419313 10 95 9150 pjnous suosJed payenb Au e au Buroeuuoo 910198 9 AU 19 UOJIMS 19euuoosip 90 891N0S 18M04 94 o1 Jemod mdu UN e SNNuvM Y CV 305 LINCOLN E DIAGRAMS F 6 CV POWER SOURCE TO AN LN 25 K444 1 F 6 699025 Ven QO3TIVISNI SI 91 AHL N3HM LOH SAVM TV 38V S IVNINS3 L 39H08 YAMOd SHI ON 31038 OL HOLIMS 310N3H 1V901 SOWNOS YAMOd JHL HOLIMS H31dVOV 310IN3H 7987 JHL JO 310v 1d393U Nid 9 IHL OL NOILdO Sc NT JHL OM 1d 9 LOANNOO HddldVQv 310IN3H 7987 JHL 30 3 10V1d393 Nid Ft SHL OL 9019 787 3HL LOANNOO ON HOLIMS S2 N1 HOLIMS JOUNOS H3MOd Ly S318VO ANY 300819313 3SH3A3H 14401 NENL SONVHO OL SAILISOd 3830819313 SMOHS INVHOVIO ON NOILVOI1ddV 40 41949 ANY LN388fD 804 Q3ZlS 38 LSNW d 18VO 9NIQTJM 319v9 30041931 ON ld OL NOILdO 77 TWNOLLdO 420334 SHIM GZ N1
19. 349 OV AOC 401 031V4 38 LSAW GOHLAW ONILVINSNI SHL WB3ldVQV IvSg3AIND NI GASNNA aasn HOV SLVINSNI SV SNOLLO3NNOO 3307108 32145 oni3sn H3d 13M 3H 3GISNI SLINDWIO IN3ON3d3QNI 11771081 38 LON AYN AYN LINOHIO HADOIHL 3uvdS Ov Ava cv 17 OV ZE LE Ov ASIE ALON MO 138 NMOHS SNOILONN ANY SNOILYNOISSC HOLO3NNOO GYVONVLS 201 OL SNOILOANNOO SHL ONIBIM LNAWdINOA 31viddOHddV AHL LINSNOOD 31875 830334 OL dH31dVQV SIHL ONITIVISNI 3H0338 410 394N0 S YAMOd JHL 40 HOLIMS YAMOd JHL NYNL NOILVH3dO 830334 H3dOud 303 GAYINOAY AJHL HON 329005 NI LNASSHd SLINOHIO TIY LON HLIM 0350 38 TIIM H3 LdvQV SIHL 830334 38IM ANY 394N0S H3MOd JHL 40 WY49VIQ 3HL LINSNOO 919 193934 830334 AHL LN3S38d SLINOYIO AHL 40 OL SNOLLO3NNOO 3 IVIN OL H3Sf 3HL MOTI OL GANOISSC SI d310V1d3O38 430333 38IM JAVH HOIHM S494N0S d3MOd NIOONIT SSN 38 OL LNVAW SI HOLO3NNOO SIHL SNOILONYLSNI NOILVTIVISNI CV 305 LINCOLN E F 9 DIAGRAMS F 9 TWIST MATE CABLE PLUG INSTALLATION INSTRUCTIONS TWIST MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS A WARNING ELECTRIC SHOCK CAN KILL TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING PLUGS ON CABLES O
20. DUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU e Fat ie ER EUR Ea fE e SH7IAE else e SUAS MAS sis PARAH 587E ASIA Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas
21. E AND CIRCUIT PROTECTION The CV 305 Control PC Board has built in diagnostic routines to alert the operator when trouble exists When a trouble condition occurs the CV 305 meter will display an error code in the form EXX where XX refers to a specific error See TROU BLESHOOTING section for an explanation of the error codes The power source is thermostatically protected against overload or insufficient cooling If the machine is overloaded the thermostat will open thermal pro tection indicator light will turn on and the output will be zero The fan will continue to run and auxiliary power will still be available The thermostat will remain open until the machine cools at which time it will close and the output will again be available The CV 305 is electronically protected against over loads and accidental short circuits The overload pro tection circuit automatically reduces the output current to a safe value when an overload is detected If the circuitry senses a short circuit it will shut off the CV 305 output The short circuit protection circuit can be reset by turning the CV 305 Power switch OFF for at least 10 seconds Remove the short before turning the Power switch ON again CV 305 LINCOLN 5 E TROUBLESHOOTING E HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in
22. ECTION Output connector is a Magnum Twist Mate receptacle Insert a mating Twist Mate plug and twist clockwise to secure The low inductance connection is typically used for short arc welding of mild steel particularly on thin materials or when using shielding gas CV 305 LINCOLN OPERATION B 5 12 HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION Output connector is a Magnum Twist MateTM receptacle Insert a mating Twist Mate plug and twist clockwise to secure The high inductance connection is more suitable for short arc welding heavier weldments or when using 75 Argon 25 shielding gas This connection produces a softer arc and a flatter bead with more wash in than the low inductance connection A spray type transfer is possible with either connection Note For GMAW processes and most FCAW processes the positive output connection goes to the wire feeder One of the negative output connections goes directly to the work 13 WIRE FEEDER RECEPTACLE 14 pin MS style receptacle for wire feeder Provides connections for auxiliary power contac tor closure remote output control wire feeder voltmeter sense lead and ground B 6 OPERATION B 6 STARTING THE MACHINE The power switch at the extreme right side of the con trol panel energizes the CV 305 ADJUSTING THE OUTPUT VOLTAGE USING THE DIGITAL METER The digital meters in the CV 305 incorporate a voltage pre set function This all
23. EN AWAY PACEMAKER 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 amp 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 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electri
24. Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Output Control not functioning on fei Local Remote switch is in the Remote position Faulty Voltage Adjust potentiometer Leads or connections open in control circuit Malfunctioning Remote Control Faulty Control PC board Poor arc striking with semiautomatic 1 Poor work connection wire feeders Improper procedures Wire feed acceleration too fast or If all recommended possible areas too slow of misadjustment have been checked and the problem persists Defective PC Board Contact your local Lincoln Authorized Field Service Facility Poor arc characteristics Control PC Board defective 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 305 LINCOLN 5 E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual OPTIONS TROUBLESHOOTING GUIDE K857 or other Remote Output Control PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Output control not functioning on 1 Local Remote switch in wrong Remote Control position Faulty Local Remote switch Faulty Remote Control poten tiometer Leads or connections ope
25. IAIGNI Qv31 GASANN HOV SLVINSNI Jounos HAMOd LY S318v2 300812313 3SH83A3H 430 H3MOd NHNL ALINV10d OL 3ALLISOd 300810313 SMOHS WVHOVIG 8 N NOLLVOMdd JO 11949 LNIHHNO Q3ZIS 38 LSNW 318VO ONIGTAM JN GZ 7 30u1NOO SLOWSY e 97 3 19 3008103 H MOL 14 OL 3ounos HAMOd 30 CIVNIWH3L HHOM OL S103NNOO NOLLO3NNOO H313IALT0A H30334 o LZ NOLLO3NNOO JWVH4 39HN0S H3MOd 5 3 ovas OYA 2 a d 298 e 114100 73 y H3H13901 LOINNOD Lo Nid Pe 39300 S39HN0S HIMOd NO 0350 LON 19 8 I AO NO co _ TI NVO 9 SIU 801188 MOOHS 21919919 ON JO jfejsui pjnous suosJed Wun e y eojeg asn yams 10euuoosip au Y 90 106 18M04 9 0 yndul CV 305 LINCOLN E F 4 DIAGRAMS CV POWER SOURCE TO A K867 K775 LN 7 F 4 699068 6 81 9 TOULNOO SLOWSY VNOILdO 773 5190 VOV HO 1605 43033 ALVINSNI ANY 9991 39 UN ATIVACIAIGNI GASANN H9V3 31V TID SNI 394N0S d3MOd LV SATEVO ANY 300819313 3543134 HO H3MOd ALIBV TOd 39NVHO
26. In case of an SCR malfunction or failure the snubber assembly should be checked Disconnect the input power to the CV 305 at the fuse box and remove the right side of the machine 1 Visually inspect the snubber PC Board assembly located below the Control PC board on the case front for overheated components or damaged compo nents OPTIONAL K857 REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohm meter between pins C and B and rotate the rheostat in the remote control The resistance reading should go from zero to 10K ohms Repeat with ohmmeter across A and B with the same results Connect ohmmeter across A and C The reading should be 10K ohms A lower reading will indicate a shorted or partially shorted rheostat A very high reading will indicate an open rheostat In either of the last two cases replace the rheostat 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 305 LINCOLN 5 n LL LGL SNOIL23NNOO YINWOLSNI 319v143934 43034 91089 vash C E SANIHOVW A09 0 Z 802 JO 57100 dOL NO 3s v3ddv 9 8 SQV31 dvL ON H3L3NOILN310d 30 HOV3 000 1 92 19 sr Ar er er
27. OL 3ALLISOd 300819313 SMOHS INVHOVIO ON 40 41949 ALNG 1N3HHF0 401 9375 38 LSAW 31899 3 9 o 91 3180 300419373 N33u9 OL TWSHAAINA 298 2 2 LE o 1 O Jun J Nid pl 3949 3ounos HIMOd I AO AO TID QUIYORW SIU 991 195 MOOHS 10 asn EIS 05190 payyenb uo e 19313 ei etj Burjoeuuoo 910198 esnj y 19 yms 10900091 ay lt Y Jemog 84 amod indui yo e CV 305 LINCOLN E DIAGRAMS F 5 CV POWER SOURCE TO AN LN 25 F 5 199025 66 81 9 PEN AHL N3HM SAVM IV S IVNIINH3IL ONITTAM 394N0S 43MOd JHL dAldVdV 104LNO9 310I N38 7989 1 30 TONAHdWV Nid vL 3HL OL Ofr1d 8 FHL LOINNOO TOWLNOD 31088 2987 V ONIS JI UI SI 104LNO9 310IN3H ON 39808 AHL 40 Nid vL SHL OL A 11O038lQ 787 AHL LOANNOO ON 3oanos d3MOd AHL 30 TONSHdWIV Nid vL OL d3ldVQV JLOIN3H 7989 V JO NOILVTIVLSNI SAYINDAY 1OH NOO 310IN38H 2989 1 30 ASN ON 3oanos d3MOd LV 3 18VO AYOM ANY 3008 03 13 3543134 HO H3MOd 3ONVHO OL 3ALLISOd 300819313 SMOHS WVHDVIC ON NOILVOITddV 30 3
28. R WHEN CONNECTING OR DISCONNECTING PLUGS TO WELDING POWER SOURCE 1 CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE APPROPRIATE CABLE SIZE PER TABLE BELOW AND SKIN CABLE JACKET TO LENGTH SPECIFIED AMERICAN EUROPEAN RANGE BOOT MARKING CAN EUROPEAN RANG CABLE SKIN LENGTH 35 50 2 1 35 50 mmj 1 INCH 25 4mm 50 70 1 0 2 0 50 70 mm 1 INCH 25 4mm 70 95 2 0 3 0 70 95 1 5 INCH 38 1mm 2 If necessary trim cable end of boot at groove s to match cable diameter Boot must fit tightly enough to seal around outside diameter of cable NOTE Some boots are designed to accommodate different cable diameters without trimming These boots do not have grooves at the cable end Soap or other non petroleum based lubricant will help to slide the boot over the cable 3 Slide rubber boot onto cable end BOOT WELDING CABLE SEE NF TRIM Slide the copper tube into the brass plug SET SCREW 5 Insert cable into copper tube 70 95 size may have 2 set screws BRASS PLUG COPPER TUBE 6 Tighten set screw s to collapse copper tube Screw s must apply firm pressure against welding cable The top of the set screw s will be nearly flush or below the surface of the brass plug after tightening 16 066 161815 7 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle CV 305 LINCOLN F 10 DIAGRAM
29. RC RAYS can burn L Wear eye ear and body protection Observe additional Safety Guidelines detailed throughout this manual CV 305 LINCOLN B 2 OPERATION B 2 GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL THERMAL PROTECTION OFF INDICATOR LIGHT CIRCUIT O O BREAKER AC CLOCKWISE ROTATION POWER GD INCREASES VOLTAGE REMOTE OUTPUT LOCAL OUTPUT VOLTAGE CONTROL VOLTAGE CONTROL WARNING INDICATES WARNING INFORMATION LOCATED ON RIGHT CASE SIDE CV 305 LINCOLN B 3 OPERATION B 3 A CAUTION When using a CV 305 power source with wire feed ers there will be a small spark if the electrode con tacts the work or ground within several seconds after releasing the trigger When used with some wire feeders with the electrical trigger interlock in the ON position the arc might restart if the electrode touches the work or ground during these several seconds GENERAL DESCRIPTION The CV 305 is a constant voltage DC power source designed for the GMAW process with limited FCAW capability as well It features an industrial rating of 315 amps 32 6 volts at 100 duty cycle It complies with the requirements for a NEMA Class 100 power source It is available from the factory in one model only with no options other than input voltage or frequency RECOMMENDED PROCESSES AND EQUIPMENT The CV 305 is capable of solid wire welding within the rated output capacity of the machine
30. REPOR ELE het EE LATE OMLMPT APSSAPREBS NTUSHILT FSU e E GUB DERNIERE GH Oa CRM ER Xe uc s a e sis HIE AMI W ous uil el all Quali Y O ai ANI gl o as slt AA usa DA dan Y Jio Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos MMIC LU THEW EKA 2 07 Vi S BET eis Ad d s Jo UN al gh AIX Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo A EU OMAR RSR ez 119 59 HEHA daig 4 Lilly gupay alg Ai EE READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRO
31. RETURN TO MAIN MENU d IDEALARC CV 305 Fin ae For use with machine Code Numbers 11177 11178 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 OPERATOR S MANUAL _ EU SSS SO 9001 LINCOLN Copyright 2006 Lincoln Global Inc e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDR
32. S CONNECTION OF NON LINCOLN WIRE FEEDERS NVHL H3H1O 39VI1OA NV SSYINOAY 4340334 3HIM A8 SI LVHL 39VLTOA AWVS AHL GALVY 38 LSNW 1109 AV 134 aaddinoa os 21 10HlNOO 1 41 0 310W34 WHO 7 01 qadiAOgHd 38 LSNW 39VLTOA IVHL AlddNS H3MOd 1VNH3LIX3 NV SANIHOVW 3AOS NO O VA SLL HO ON 43023231 AHL 9 38 LSNW 39Hf1OS H3MOd HN 11 NO LN3S3Hd 38 LON AYN CE LE SNOILO3NNOO 430334 38IM NIOONIT NON T H3MOd LNdNI 430334 34IM aaddinoa os 41 10HlNOO 1 41 310W34 WHO 01 1 1 398 05 H3MOd 139 01 311 ADVLIOA ON 1102 Av 13H N3dO A11VWHON LOVLNOO AV134 05 12 Addns 5 OWACH O VASIL vu f 10HLNO9 HOLOVINOO 1ndino t 430334 3HIM NTOONIT NON N 1 41 0 aounos H3MOd 139 OL 25070 SIOVINOO H3MOd LNdNI 430334 CV 305 LINCOLN E 05 12 4 v TOHINOO HOLOVINOO 4 indino F 10 duadldVav lt 5 2987 319VLd3903H 430334 Nid vl 194NOS H3MOd YAldVGV lt 5 2987 319VLd3O3H 41042114 Nid v E 194NOS YAMOd ADYNOS H3MOd 139 OL SLOVINOO 30 135 V 35019 LVHL 5 3HIM 401 ADYNOS H3MOd LAD OL ADVLIOA V AlddNS LVHL SH3aaad 2
33. UTPUT CONNECTIONS for connection of work and electrode cables Connection of Remote Control K857 NOTE The K864 Remote Control Adapter is required to install the K857 Plug the K864 Remote Control Adapter into the power source s 14 pin receptacle Plug the K857 Remote Control into the 6 pin receptacle of the K864 adapter If possible tape the Remote cable to the heavy output leads so they can protect the smaller Remote cable from damage and abuse OUTPUT CONNECTIONS Output cables must have Magnum Twist Mate plugs for connection to the CV 305 Order K852 95 for con necting 2 0 3 0 70 95 mm2 cables Refer to 18737 for instructions on installing these plugs Use the shortest possible cable lengths See Table A 1 for recommended cable sizes based on length Connect the positive output lead to the terminal marked The negative output lead can be hooked to either the low inductance terminal marked NL or the high inductance terminal marked _ TABLE A 1 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable Lengths up to Machine Size 150 ft 150 to 200 ft 315 100 2 0 70mm 3 0 95mm CV 305 LINCOLN 5 Ag INSTALLATION PARALLELING The CV 305 is not designed to be paralleled with itself or 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
34. automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc ray
35. c current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running e 2 d 3 Do not place your body between the electrode and work cables If
36. e 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 Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially 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 lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick
37. employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Mar 95 SAFETY WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above
38. eut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 5 Mar 93 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product ee
39. for each circuit present in the wire feeder receptacle Not required when using a standard wire feeder input cable such as a K480 with a Lincoln wire feeder TWIST MATE CABLE PLUG MALE For 1 0 2 0 50 70 mm Cable For 2 0 3 0 70 95 mm Cable K852 70 K852 95 TWIST MATE CABLE RECEPTACLE FEMALE For 1 0 2 0 50 70 mm Cable For 2 0 3 0 70 95 mm Cable K1759 70 K1759 95 COMPATIBLE LINCOLN EQUIPMENT The CV 305 is intended for use with the LF 72 LN 7 LN 742 and LN 25 wire feed units Use the Cables Kits listed below to make connection easily Requires K1797 XX Control Cable Included with Wire Feeder Requires K864 Remote Control Adapter and K484 Jumper Plug Kit Requires K591 Input Cable LN 742 LN 742H CV 305 LINCOLN 5 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts GENERAL MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot with prema ture tripping of thermal protection Blow out the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build up on inter nal parts MACHIN
40. g cables of the proper capacity and make sure all connec tions are tight to minimize this effect 6 42 VOLT CIRCUIT BREAKER Protects the 42 volt 41 42 circuit in the wire feeder receptacle from overloads and shorts If this circuit breaker opens the CV 305 will work normally However any equipment powered by the 42 volt circuit will not work 115 VOLT CIRCUIT BREAKER Protects the 115 volt 31 32 circuit in the wire feed er receptacle from overloads and shorts If this cir cuit breaker opens the CV 305 will work normally However any equipment powered by the 115 volt circuit will not work LOCAL REMOTE SWITCH Determines whether the welding voltage is con trolled at the CV 305 or controlled remotely by a remote output control such as a K857 LINCOLN B 5 9 WIRE FEEDER VOLTMETER SWITCH 10 11 This switch selects the polarity of the wire feeder voltmeter if so equipped When welding electrode positive MIG Outershield and some Innershield processes set the switch to When welding electrode negative most Innershield electrodes set the switch to This switch has no effect on the welding polarity In fact if the wire feeder being used does not have a voltmeter the setting of this switch has no effect POSITIVE OUTPUT CONNECTION Output connector is a Magnum Twist Mate receptacle Insert a mating Twist Mate plug and twist clockwise to secure LOW INDUCTANCE NEGATIVE CONN
41. he CV 305 above it TILTING Do not place the machine on a surface that is inclined enough to create a risk of the machine falling over CV 305 LINCOLN 5 A 3 INSTALLATION A 3 FIELD INSTALLED OPTIONS For installation of compatible field installed options see the ACCESSORIES section of this manual and refer to the instructions included with those options REQUIRED EQUIPMENT CONTROL CABLE CONNECTIONS Follow the instructions below which are appropriate for the wire feeder that will be used LF 72 to CV 305 a Turn the CV 305 Power switch to the OFF posi tion b Connect the LF 72 control cable to the wire feed er receptacle on the CV 305 c See OUTPUT CONNECTIONS for connection of work and electrode cables LN 7 to CV 305 a Turn the CV 305 Power switch to the OFF posi tion b Connect the LN 7 control cable to the wire feeder receptacle on the CV 305 c See OUTPUT CONNECTIONS for connection of work and electrode cables LN 25 to CV 305 a Turn the CV 305 Power switch to the OFF posi tion b Plug a K484 jumper plug into the CV 305 wire feeder receptacle c See OUTPUT CONNECTIONS for connection of work and electrode cables WARNING The output terminals are energized at all times when the K484 is plugged in LN 742 to CV 305 a Turn the CV 805 Power switch to the OFF posi tion b Connect the LN 742 control cable to the wire feeder receptacle on the CV 305 c See O
42. ht on the case front see Figure B 1 The fan will continue to run to cool the power source No welding is possible until the machine is allowed to cool and the Thermostatic Protection Light goes out CV 305 LINCOLN C1 ACCESSORIES 1 FACTORY INSTALLED OPTIONS ACCESSORIES There are no factory installed options accessories on the CV 305 FIELD INSTALLED OPTIONS REMOTE VOLTAGE CONTROL K857 The K857 consists of a control box with 25 feet 7 6 m of four conductor cable Installation of a K857 Remote Voltage Control in the CV 305 requires a K864 Remote Control Adapter Refer to the instruc tions provided with the K857 for hookup to the CV 305 When properly connected and with the CV 305 Local Remote Switch in the Remote position the K857 functions the same as the CV 305 Voltage Adjust control enabling minimum to maximum output voltage adjustment of the CV 305 1 Also availible is a K857 1 w 6 Pin MS Type Amphenol Plug and 100 feet 30 4m cable TWO CYLINDER UNDERCARRIAGE K874 Platform type undercarriage that can accommodate either one or two gas bottles or one gas bottle and a Magnum water cooler The CV 305 lifting eye is not functional when the K874 undercarriage is installed UNIVERSAL ADAPTER K867 Provides a means of connecting auxiliary equipment to the wire feeder receptacle on the CV 305 power Source Consists of a 14 pin MS type Amphenol plug with 8 inch 0 2 meter long flex leads one
43. ies and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
44. ima Es H _ ey tr I sk 9 3 __22 3 2 9 Po Nid INvHOVIG ONIHIM 21VIHdOHddV 339 LN3INdIQD3 NI LN3S3Hd SC 38 LON AYN HO AVIN HOV3 NV AINO 3oN3u34a3u 401 031517 38v SNOILONNA A18N3SSV 91999 7 31870 390819573 01 6181 OL 339333 jHIM one JON3HdNV d v 39410 d3MOd CV 305 LINCOLN E DIAGRAMS F 8 K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS F 8 985615 06 91 M3IA INOH 318VO Nld t ANY Hu 310v1d393H NId t L8 W gt 6 9 jdVdS N QN9 H rz Ride MAIA uv3d 01 318vO Nld vL ONY 1 310V1d303H L8 N ER v d 9129 3UVdS N 2 0 E 2871 ON5 8 ist co V OV 7M AGOW ONIG T3M 3uvds 18 18 JOH1NOO JAQON z8 16 TOHLNOO LNdLNO _ 92 jouiNOO 1ndinO 97 TOHINOO INdINO 24 42594 4inodioudoDiMi 1 NOLLO3NNOO SISSVHO ____________ NOILONNA quvaNvis IN3lNdI1O3 HNOA NI LN3S3Hd 38 LON AVIA HO AYN HOV ANY AINO 30N3H333H 83151 SNOILONN4 9 INVHOVIG ONIHIM 31VIHdOHddY 339 9 V ER NN X WS KS SE EE KR ES Ke 8 ES Nid 431V
45. n necting or disconnecting output cables wire feeder or remote connections or other equipment Do not touch electrically hot parts Always connect the Idealarc CV 305 grounding terminal located on the welder base near the reconnect panel to a good electrical earth ground SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely circulate in through the side louvers and out through the rear louvers Dirt dust or any foreign material that can be drawn into the welder should be kept at a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shut downs Idealarc CV 305 power sources carry an IP21S enclosure rating They are rated for use in damp dirty environments subject to occasional falling water such as rain INSTALLATION INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the welder nameplate Gain access to the input reconnect panel by removing the right case side of the CV 300 side nearest to the Power switch Have a qualified electrician connect the input leads to L1 L2 and L3 of the input reconnect panel in accor dance with the National Electrical Code all local codes and the connection diagram located on the inside of the right case side Use a three phase line The frame of the welder must be grounded A ground terminal marked with the symbol located on the base of the machine is
46. n in control circuit Faulty Control PC board Output Control not functioning on the 1 Local Remote switch in the If all recommended possible areas wrong position of misadjustment have been checked and the problem persists Faulty Local Remote switch Contact your local Lincoln Authorized Field Service Facility Faulty Voltage Adjust potentiometer A 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 305 LINCOLN 5 E 7 TROUBLESHOOTING E 7 Procedure for Replacing PC Boards A WARNING ELECTRIC SHOCK can Have a qualified individual install and service this equipment Turn the power source input power off at the disconnect switch before work ing on this equipment Do not touch electrically hot parts Before replacing a PC board which is suspected of being defective visually inspect the PC board in ques tion for any electrical or mechanical damage to any of its components and conductors on the back of the board a If there is no visible damage to the PC board install a new one and see if this remedies the prob lem If the problem is remedied reinstall the old PC board to see if the problem still exists If it does no longer exist with old PC board 1 Check the PC board harness connector
47. ontrols and Gettngs B 4 thru 5 starting the Machine B 6 Adjusting the Output Voltage using the Digital Meter B 6 Local Remote Switch Operation B 6 UE ed UE B 6 Overload Protection EET B 6 finu Section C Factory Field Installed Options 1 Compatible Lincoln Equipment C 1 ernennen Section D Safety Precautions usines D 1 Generali D 1 Machine and Circuit Protection D 1 Troubleshooting Section E Safety Pr cautions UII EE urine E 1 How to Use Troubleshooting Guide 1 Built in Diagnostic Routines and Error Codes Troubleshooting Guide E 2 Machine Troubleshooting Guide E 3 Options Troubleshooting Guide ss E 6 Procedure for Replacing PC 7 Control and Meter PC Board Troubleshooting Procedures E 7 Output Voltage Fault Protection Snubber Circuit and K857 Remote Control Checks E 8 NET Il
48. ows the operator to set the desired welding voltage before striking an arc The digital meters can also display welding current To make use of the voltage preset function the Volts Amps switch must be in the Volts position Turn the Voltage Adjust knob until the digital meter displays the desired weld ing voltage See below if an external power source remote control is installed When an arc is struck the digital meter displays the actual welding voltage as measured at the CV 305 output termi nals NOTE The arc voltage at the electrode may be as much as two volts different from the CV 305 output terminal voltage This is due to voltage drops present in the welding cables cable connections and welding gun To minimize these drops use cables of ade quate capacity and make sure all connections are clean and tight Because of these voltage drops you may have to preset the CV 305 for a slightly higher welding voltage than your procedure calls for To read welding current set the Volts Amps switch to the Amps position The welding current will be displayed whenever an arc is struck LOCAL REMOTE SWITCH OPERATION If voltage control is desired at the CV 305 the Local Remote switch must be in the Local position The Voltage Adjust on the front panel can be used to adjust the CV 305 output The remote control even if connected will have no effect if the switch is in the Local position To use a remote control such
49. provided for this purpose See the National Electrical Code for details on proper grounding methods Fuse the input circuit with the recommended super lag fuses Choose an input and grounding wire size according to local codes or use the following table Delay type circuit breakers may be used in place of fuses Using fuses or circuit breakers smaller than recommended may result in nuisance tripping from welder inrush currents even if not welding at high cur rents RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 C Fuse Input Type 75 C Copper Super Lag or Breaker Ampere Copper Wire in Ground Wire in Rating on Conduit AWG Conduit AWG Nameplate IEC Sizes IEC Sizes TC 1Also called inverse time or thermal magnetic circuit breakers circuit breakers which have a delay in tripping action that decreases as the magni tude of the current increases Input Voltage A CAUTION DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment the surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not more than 5 90 150mm beyond the equipment on all sides Frequency 208 60 230 60 575 60 40 STACKING The CV 305 may be stacked three high provided the bottom machine is on a stable hard level surface Be sure that the two pins in the roof fit into the slots in the base of t
50. r 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 305 LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual MACHINE TROUBLESHOOTING GUIDE Not all trouble conditions can be recognized by the PC board and displayed as error codes The following guide covers most other trouble conditions PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Machine has no output 1 Secondary contactor circuit 2 and 4 wire feeder receptacle not working Electrode or work lead loose or broken Defective PC Board Protective circuits operating due to output short circuit If using an LN 25 K484 jumper plug kit not making connection between 2 amp 4 in wire feeder receptacle If welding with 1 16 aluminum wire and machine is flashing EOO If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Machine has minimum output 1 Voltage Control misconnected Machine has low output and no con 1 Open in feedback circuitry trol Faulty PC Board Voltage Adjust potentiometer circuit open lead 75 CAUTION If for any reason you do not understand the tes
51. s or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 iv SAFETY PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lec
52. s manual BUILT IN DIAGNOSTIC ROUTINES AND ERROR CODES The CV 305 Meter PC Board displays error codes when certain trouble conditions exist The error codes trouble conditions and possible remedies are listed below ERROR TROUBLE REMEDY CODE Output short circuited 1 Turn power off Remove short circuit May be encountered while 2 a Turn power off to clear error Use recommended starting or welding with 1 16 alu Wfs voltage settings and angle of approach of wire minum wire to work b If problem still persists call Local Lincoln Authorized Field Service Facility Thermostat circuit has opened Allow machine to cool Be sure to provide adequate ventilation for machine See PC Board Troubleshooting Procedure Voltage Adjust potentiometer not 1 Check wiring between Voltage Adjust and the connected Control PC Board Remote Control not functioning 2 See Options Troubleshooting Guide correctly Input line voltage too low Turn power off Insure machine input voltage is within Specifications Turn power back on Input line voltage too high Turn power off Insure machine input voltage is within Specifications Turn power back on CM Overload condition Reduce load on machine If after attempting the remedies listed above the error condition still exists the problem may be with the wiring in the following areas the shunt leads 218 and 219 or voltage feedback leads 213B 214B and 224B CAUTION If fo
53. s or to hot spatter or metal FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 6 5 LINCOLN 5 Shielding gases used for arc welding displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your
54. t 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 305 LINCOLN 5 E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION PROBLEMS Thermal Protection Indicator light is 1 Thermostat circuit has opened on Faulty Control PC Board Machine does not have maximum Faulty Control PC Board output Voltage Adjust potentiometer defective Voltage Adjust potentiometer leads open Machine will not shut off Defective power switch Variable or sluggish welding arc Poor work or electrode If all recommended possible areas connection of misadjustment have been checked and the problem persists Welding leads too small Contact your local Lincoln Authorized Field Service Facility Welding current or voltage too low Defective SCR bridge Digital meters do not light Faulty Meter PC board or Digital meter display is incorrect 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 305 LINCOLN 5 5 TROUBLESHOOTING E 5 Observe all Safety
55. the electrode cable is on your right side the work cable should also be on your right side AR N Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or
56. trode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d
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