Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii 3 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durab...
Page 4 - iii; WELDING and CUTTING; Refer to
iii SAFETY iii 4 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground th...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
-6- Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS; Page
TABLE OF CONTENTS Page Safety Precautions .............................................................................................................2-5Introductory Information .......................................................................................................7Meaning of Graphi...
Page 8 - MEANINGS OF GRAPHIC SYMBOLS
MEANINGS OF GRAPHIC SYMBOLS The CV 500-I nameplate has been designed to use international symbols in describing the function of the variouscomponents. Below are the symbols used. – 8 – V V Input (Power) On Off Output Voltage Control (Export Model) Increase / Decrease of Output Voltage OUTPUT CONTROL...
Page 10 - NEMA EW 1
– 10 – Three Phase Power RATING PLATE Transformer Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection Shielded Metal Arc Welding Designates Welder can be used in environments withincreased hazard of electric shock. (European model only) Flux Cored Arc Welding Degree of prot...
Page 12 - Operational Features & Controls
GENERAL MACHINE DESCRIPTION The CV 500-I is an SCR controlled three phase DCpower source. It is designed with a single rangepotentiometer control. The CV500-I has two models - an Export model and aEuropean model. The Export model complies withNEMA EW 1 requirements and the European modelcomplies wit...
Page 15 - TECHNICAL SPECIFICATIONS
– 15 – TECHNICAL SPECIFICATIONS ModelTypeFrequency Output Rating AmperesVolts NEMA EW1 IEC 974-1 Duty Cycle Output Range (Min.) (Max.) Max. O.C.V. Input Ratings Standard Voltages Single Voltages (Available)Rated CurrentInput kVAPower FactorEfficiencyIdle CurrentIdle Power Optional Features Remote Co...
Page 16 - INSTALLATION; Safety Precautions; Input Power Connections; FALLING EQUIPMENT
– 16 – INSTALLATION Safety Precautions LOCATION The machine should be located in a clean, dry placewhere there is free circulation of clean air such that airmovement in through the front and out through theback will not be restricted. Dirt and dust that can bedrawn into the machine should be kept to...
Page 17 - Output Cable Connections; Output Cables; CABLE SIzES FOR COMBINED LENGTH OF; Installation of Field Installed Options; Tu r n t h e p o w e r s w i t c h o f t h e; O F F; before installing plugs on cables or; CAUTION
– 17 – Failure to follow these instructions can cause immedi-ate failure of components within the machine. When powering welder from a generator be sure toturn off the welder first, before generator is shut downin order to prevent damage to welder. Output Cable Connections The output leads are conne...
Page 18 - WIRE FEEDER CONTROL CABLE CONNECTIONS
– 18 – UNDERCARRIAGES (K817P, K841) For easy moving of the machine, optional undercar-riages are available with polyolefin wheels (K817P) ora platform undercarriage (K841) with mountings fortwo gas cylinders at rear of welder. Install per instructions provided with undercarriage. Installation of Equ...
Page 19 - POWER SOURCE OPERATION; Duty Cycle and Time Period; Amps; STARTING THE MACHINE; CONTROL SETTINGS & DESCRIPTIONS; OUTPUT VOLTAGE CONTROL DIAL; OPERATING INSTRUCTIONS
– 19 – POWER SOURCE OPERATION Duty Cycle and Time Period The CV 500-I is rated at the following duty cycles: Duty Cycle* Amps Volts 100% 400 36 60% 450 38 50% 500 40 * Based upon a 10 minute time period. (i.e., for 60% duty cycle, it is 6 minutes on and 4 minutes off). Overloading the power source m...
Page 21 - MAINTENANCE; Routine Maintenance
– 21 – 220 VAC AUXILIARY POWER FOR WATER COOLER A Continental European receptacle (220V Schukot y p e ) i s l o c a t e d o n t h e r e a r p a n e l f o r s u p p l y i n g220VAC to a water cooler. A 2 amp circuit breakerwhich is also located on the rear panel protects thiscircuit from excessive ov...
Page 22 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
TROUBLESHOOTING 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. CAUTION This Troubleshooting Guide is provided to h...
Page 23 - TROUBLESHOOTING GUIDE; Trouble
– 23 – TROUBLESHOOTING GUIDE Trouble Cause What To Do Input contactor (CR1 chatters). Machine input contactor does notoperate. Machine input contactor operates,but no output when trying to weld. Machine has minimum output andno control. Machine has high output and nocontrol. 1. Faulty input contacto...
Page 26 - ELECTRIC SHOCK
– 26 – Procedure for Replacing PC Boards When a PC board is suspected to be defective, thefollowing procedure must be followed: 1. Visually inspect the PC board. If the board has fuses, check to see if any are blown. Are any ofthe components damaged? Is a conductor on theback side of the board damag...
Page 31 - NOTES