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Lincoln Electric IM481-B manual

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Table of contents for the manual

  • Page 1

    C V 500-I $%' ) $'S("#*! For use with machines Codes 10088 thru 10092, 10277, 10278, 11356 " February, 2011 (054BG4>4<3A=<.=C Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installat[...]

  • Page 2

    $'## >=E4@434?C8>;4<B 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

    88 (). 88 3 ARC R A Y S can b ur n. 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. I standards. 4. b . Use suitable clothing made from durable flame-resistant material to pro[...]

  • Page 4

    888 (). 888 4 FOR ELECTRIC ALL Y pow er ed equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b . Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with t[...]

  • Page 5

    8D (). 8D %'I*)$#((Q')I Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: (K@4BJ%=C@(=C3064!S@2 1. Protegez-vous contre la se[...]

  • Page 6

    -6- Thank Y ou 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 and keep it handy for quick reference. Pa[...]

  • Page 7

    ) !$$#)#)( Page Safety Precautions .............................................................................................................2-5 Introductory Information .......................................................................................................7 Meaning of Graphic Symbols .....................[...]

  • Page 8

    "##($'%(."$!( The CV 500-I nameplate has been designed to use international symbols in describing the function of the various components. Below are the symbols used. – 8 – V V <>CB%=E4@ $< $55 $CB>CB+=:B064=<B@=:F>=@B"=34: ?[...]

  • Page 9

    – 9 – 8@2C8B@4094@ '*)' ' 867)4;>4@0BC@4 )'"!%'$))$#!) +=:B;4B4@ +$!)")'(,) %=A8B8D4:42B@=34 #460B8D4:42B@=34[...]

  • Page 10

    – 10 – )7@44%70A4%=E4@ ')#%!) )@0<A5=@;4@ '42B8584@ '42B85843$CB>CB =<AB0<B+=:B06470@02B4@8AB82 !8<4=<<42B8=< (784:343"4B0:@2,4:38<6 4A86<0B4A ,4:34@ 20< 14 CA43 8< 4<D8@=<;4<B[...]

  • Page 11

    – 11 – ,0@<8<634<B85820B8=< ,'###))$# (86<85G8<6B740@B7@=C<3=<<42B8=< ')'$*#$##)$# (86<85G8<6B7470AA8A@=C<3=<<42B8=< ((('$*#?[...]

  • Page 12

    #'! "#('%)$# The CV 500-I is an SCR controlled three phase DC power source. It is designed with a single range potentiometer control. The CV500-I has two models - an Export model and a European model. The Export model complies with NEMA EW 1 requirements and the European model complies [...]

  • Page 13

    *-!'.%$,'$##)$#( Th e p ow er s ou rce is eq ui pp ed t o f ur nis h n om in all y 115 volt AC and 42 volt AC auxiliary power for operat- ing wire feeding equipment, etc. The auxiliary power is available at the 14-pin MS-style connector recepta- cle on the control panel and/or at a terminal strip behind th[...]

  • Page 14

    %'!!!# There are no provisions on the CV 500-I to permit par- alleling. $R$%)$# (Factory installed only) The CV 500-I Diode option is required to utilize the cold start and cold electrode sensing features of the NA-3, NA-5 or NA-5R. When this option is not used with an NA-3, NA-5 or NA-5R, see the CV 500-I / NA[...]

  • Page 15

    – 15 – )#! (% )$#( Model T ype Frequency Output Rating Amperes V olts NEMA EW1 IEC 974-1 Duty Cycle Output Range (Min.) (Max.) Max. O.C.V . Input Ratings Standard V oltages Single V oltages (Available) Rated Current Input kV A Power Factor Efficiency Idle Current Idle Power Optional Features Remot[...]

  • Page 16

    – 16 – #() !! )$# (054BG%@420CB8=<A !$)$# The machine should be located in a clean, dry place where there is free circulation of clean air such that air movement in through the front and out through the back will not be restricted. Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure t[...]

  • Page 17

    – 17 – Failure to follow these instructions can cause immedi- ate failure of components within the machine. When powering welder from a generator be sure to turn off the welder first, before generator is shut down in order to prevent damage to welder. $CB>CB01:4=<<42B8=<A The output leads are connected to the output term[...]

  • Page 18

    – 18 – *#'''( %  For easy moving of the machine, optional undercar- riages are available with polyolefin wheels (K817P) or a platform undercarriage (K841) with mountings for two gas cylinders at rear of welder. Install per instructions provided with undercarriage. <AB[...]

  • Page 19

    – 19 – %$,'($*'$%' )$# CBGG2:40<3)8;4%4@8=3 The CV 500-I is rated at the following duty cycles: CBGG2:4 ;>A + =:BA 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[...]

  • Page 20

    – 20 – $*)%*)$#)'$!O!$!'"$)P(,) The Output Control toggle switch on the control panel labeled “Local-Remote” gives the operator the option of controlling the output at the machine control panel or at a remote station. For remote control, the toggle switch is set in the “Remote” position[...]

  • Page 21

    – 21 – +*-!'.%$,'$',)'$$!' A Continental European receptacle (220V Schuko type) is located on the rear panel for supplying 220VAC to a water cooler. A 2 amp circuit breaker which is also located on the rear panel protects this circuit from excessive overload[...]

  • Page 22

    )'$*!($$)# If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your !=20:!8<2=:<CB7=@8H4384:3(4@D824028:8BG for technical troubleshooting assistance before you proceed. *)$# This Troubleshooting Guide is provided to help [...]

  • Page 23

    – 23 – )'$*!($$)#R* )@=C1:4 0CA4 ,70B)== Input contactor (CR1 chatters). Machine input contactor does not operate. Machine input contactor operates, but no output when trying to weld. Machine has minimum output and no control. Machine has high output and no control. 1. Faulty input contactor (CR1). 2.[...]

  • Page 24

    – 24 – )@=C1:4 0CA4 ,70B)== Machine has low output and no con- trol. Machine does not have maximum output. Machine will not shut off. Variable or sluggish welding arc. Output control not functioning on the machine. 1. Output Control “Local-Remote” switch (S2) in wrong position. 2. Output Control switch faulty. 3. Open in feedbac[...]

  • Page 25

    – 25 – )@=C1:4 0CA4 ,70B)== Output control not functioning on “Remote” control. Poor arc striking with semiautomatic or automatic wire feeders. Poor arc characteristics. 1. Output Control switch in wrong position. 2. Faulty Output Control switch. 3. Faulty remote control poten- tiometer. 4. Leads or connections open in control c[...]

  • Page 26

    – 26 – %@=243C@45=@'4>:028<6%=0@3A When a PC board is suspected to be defective, the following procedure must be followed: 1. Vi su al ly i ns pe ct t he P C b oa rd . I f t he b oa rd h as fuses, check to see if any are blown. Are any of the components damaged? Is a conductor on the back side of the board damaged? [...]

  • Page 27

    – 27 – '"$)$#)'$! Disconnect the remote output control and connect an ohmmeter across 75 and 76 and rotate the rheostat in the remote control. The resistance reading should go from zero to 10K ohms. Repeat with ohmmeter across 77 and 76 with same results. Connect ohmmeter across 75 and 77. The reading s[...]

  • Page 28

    .800 .385 .415 .167 .207 .503 .513 .150 .200 BRASS .600 .553 TIN PLATED COPPER TUBE .740 N.B. N.A. NOTES: N.A. DISPLACEMENT HOLE PERMISSIBLE. RUBBER BOOT MARKED WITH "70-95" (2)SET SCREWS RAISED TAB NOT IMPORTANT. N.B. RELATIONSHIP BETWEEN SET SCREWS AND M15479-1 9-20-91J .800 .385 .415 .167 .207 .503 .513 .150 .200 BRASS .600 .553 TIN PL[...]

  • Page 29

    POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG TO SNUBBER BOARD SHUNT P5 221222 223 204 220 204 204 204 220 D1D2 D3 SCR1SCR2 SCR3 G1G2G3 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 _ + X 1 X 2 X 3 GATE _ + POWER RECTIFIER BRIDGE DIAGRAM 1 PLUG[...]

  • Page 30

    – 30 – NOTE: This diagram is for reference only. It may not be 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. Enhanced Diagram[...]

  • Page 31

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  • Page 32

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  • Page 33

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF A CTURER’S INS TRUCTION FOR THIS EQ UIPMENT AND THE CONSUMABLES T O BE USED AND FOLL O W Y OUR EMPL O YER’S SAFETY PRA CTICES. SE RECOMIEND A LEER Y ENTENDER LA S INS TRUCCIONES DEL F AB[...]

  • Page 34

    W ARNING A VISO DE PREC A UCION A TTENTION W ARNUNG A TENÇ Ã O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREEND A A S INS TRUÇÕES DO F ABRIC ANTE P ARA ES TE EQUIP AMENT O E A S P AR TES DE USO , E SIGA A S PRÁ TIC AS DE SE GUR ANÇ A DO EMPREG ADOR. • Kee p yo ur h ead out of fum es. • Use ven tila tio n or[...]

  • Page 35

    • 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 • World's Leader in Welding and Cutting Products •[...]