RETURN TO MAIN INDEX
IM500-A
IDEALARC ® CV-300 October, 2002
For use with machine Code Numbers 10180, 10181
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2002 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN 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 & 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 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. 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
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
6. Eloigner les matériaux inflammables ou les recouvrir afin de
dans ce manuel aussi bien que les précautions de sûreté
prévenir tout risque d’incendie dû aux étincelles.
générales suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines à soud-
vapeurs du solvant pour produire du phosgéne (gas forte-
er parce que la tension entre les deux pinces peut être le
ment toxique) ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché Ã
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? 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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick 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:
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 vi
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Select Suitable Location ........................................................................................A-2
Input Connections..................................................................................................A-2
Field Installed Options ...........................................................................................A-3
Required Equipment - Control Cable Connections................................................A-3
Output Connections. ..............................................................................................A-3
Paralleling .............................................................................................................A-4
Connection of Auxiliary Equipment to Wire Feeder Receptacle ............................A-4
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-2
Recommended Processes and Equipment ...........................................................B-2
Operational Features and Controls........................................................................B-2
Design Features ....................................................................................................B-2
Limitations..............................................................................................................B-2
Power Source Operation .......................................................................................B-2
Duty Cycle .............................................................................................................B-2
Controls and Settings ............................................................................................B-3
Graphic Symbols ...................................................................................................B-4
Output Panel Connections.....................................................................................B-5
Starting the Machine..............................................................................................B-6
Adjusting the Output Voltage using the Digital Meter ............................................B-6
Local/Remote Switch Operation ............................................................................B-6
Auxiliary Power ......................................................................................................B-6
Overload Protection ...............................................................................................B-6
Accessories .....................................................................................................Section C
Factory/Field Installed Options ..............................................................................C-1
Compatible Lincoln Equipment..............................................................................C-1
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
General Maintenance ............................................................................................D-1
Machine and Circuit Protection..............................................................................D-1
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Built-in Diagnostic Routines and Error Codes -Troubleshooting Guide.................E-2
Machine -Troubleshooting Guide...........................................................................E-3
Options -Troubleshooting Guide............................................................................E-6
Procedure for Replacing PC Boards......................................................................E-7
Control and Meter PC Board Troubleshooting Procedures ...................................E-7
Output Voltage, Fault Protection, Snubber Circuit and K857 Remote Control Checks....................E-8
Diagrams ..........................................................................................................Section F
Parts Manual ....................................................................................................Appendix
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATIONS � IDEALARC CV-300
INPUT - THREE PHASE ONLY
Code
Standard Input Current at
Number
Voltage Rated Output
10180
208/230/460/3/60 100% Duty Cycle 66/60/30
60% Duty Cycle 67/61/31
10181
230/460/575/3/60 100% Duty Cycle 60/30/24
60% Duty Cycle 61/31/25
RATED OUTPUT
Volts at Rated Amperes
Duty Cycle Amps
32
100% Duty Cycle 300
NEMA Class I (100)
36
60% Duty Cycle 400
32
100% Duty Cycle 300
OUTPUT
Auxiliary Power
Welding Current/Voltage Range Normal Open Circuit Voltage
42 Volts AC, 10 Amps
(Continuous) 10-43
50A/7V - 400A/37V MAX OCV: 50 115 Volts AC, 5 Amps
DC ( Both Circuit Breaker Protected)
MISC. INFORMATION
Idle Current - Amps
Efficiency at 100% Load Input kVA
11/10/5
78% 60% Load - 24.1
100% Load - 23.8
Idle Power Power Factor at 100% Load
800W .61
PHYSICAL DIMENSIONS
Height Width Depth Weight
21.5 in. 19.5 in. 27.0 in.
(Lift bail, add 3.12 in) 300 lbs
(137 kg)
546 mm 495 mm 686 mm
(Lift bail, add 80 mm)
CV-300
A-2 A-2
INSTALLATION
Read entire installation section before starting INPUT CONNECTIONS
installation.
Be sure the voltage, phase, and frequency of the input
SAFETY PRECAUTIONS power is as specified on the welder nameplate.
WARNING Gain access to the input reconnect panel by removing
the right case side of the CV-300 (side nearest to the
ELECTRIC SHOCK can kill. Power switch.)
� Only qualified personnel should
perform this installation.
Have a qualified electrician connect the input leads to
� Turn the input power OFF at the discon-
nect switch or fuse box before working on L1, L2, and L3 of the input reconnect panel in accor-
this equipment.
dance with the National Electrical Code, all local
� Turn the Power switch on the CV-300 codes, and the connection diagram located on the
“OFF� before connecting or disconnect-
inside of the right case side. Use a three phase line.
ing output cables, wire feeder or remote
connections, or other equipment.
The frame of the welder must be grounded. A ground
� Do not touch electrically hot parts.
terminal marked with the symbol located on the
� Always connect the Idealarc CV-300
base of the machine is provided for this purpose. See
grounding terminal (located on the welder
base near the reconnect panel) to a good the National Electrical Code for details on proper
electrical earth ground.
grounding methods.
SELECT SUITABLE LOCATION 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.
Place the welder where clean cooling air can freely
"Delay type"1 circuit breakers may be used in place of
circulate in through the side louvers and out through
fuses. Using fuses or circuit breakers smaller than
the rear louvers. Dirt, dust or any foreign material that
recommended may result in "nuisance" tripping from
can be drawn into the welder should be kept at a
welder inrush currents even if not welding at high cur-
minimum. Failure to observe these precautions can
rents.
result in excessive operating temperatures and
nuisance shut-downs. Idealarc CV-300 power sources
RECOMMENDED INPUT WIRE AND FUSE SIZES
carry an IP23 enclosure rating. They are rated for use
in damp, dirty environments subject to occasional Type 75°C
falling water such as rain. Fuse Input Type 75°C Copper
(Super Lag) Ampere Copper Wire in Ground Wire in
Input
STACKING Voltage / or Breaker Rating on Conduit AWG Conduit AWG
Size Nameplate (IEC) Sizes
Frequency (IEC) Sizes
4 (25 mm2) 8 (10mm2)
The CV-300 may be stacked three-high provided the 100 66
208/60
bottom machine is on a stable, hard, level surface. Be 4 (25 mm2) 8 (10mm2)
90 60
230/60
sure that the two pins in the roof fit into the slots in the
10 (6mm2) 10 (6mm2)
50 30
460/60
base of the CV-300 above it.
10 (6mm2) 10 (6mm2)
40 24
575/60
4 (25 mm2) 8 (10mm2)
100 66
200/50/60
TILTING
4 (25 mm2) 8 (10mm2)
90 61
220/50/60
Do not place the machine on a surface that is inclined 4 (25 mm2) 8 (10mm2)
90 58
230/50/60
enough to create a risk of the machine falling over. 8 (10mm2) 10 (6mm2)
60 35
380/50/60
8 (10mm2) 10 (6mm2)
50 33
400/50/60
8 (10mm2) 10 (6mm2)
50 32
415/50/60
10 (6mm2) 10 (6mm2)
50 31
440/50/60
10 (6mm2) 10 (6mm2)
40 26
500/50/60
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.
CV-300
A-3 A-3
INSTALLATION
Connection of Remote Control (K857)
FIELD INSTALLED OPTIONS
NOTE: The K864 Remote Control Adapter is required
For installation of compatible field installed options
to install the K857.
(see the ACCESSORIES section of this manual and
refer to the instructions included with those options.
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.
REQUIRED EQUIPMENT-CONTROL If possible, tape the Remote cable to the heavy output
CABLE CONNECTIONS leads, so they can protect the smaller Remote cable
from damage and abuse.
Follow the instructions below which are appropriate
for the wire feeder that will be used. OUTPUT CONNECTIONS
LN-7 to CV-300 Output cables must have Magnum Twist-Mateâ„? plugs
for connection to the CV-300. Order K852-95 for con-
a) Turn the CV-300 Power switch to the "OFF" posi- necting 2/0-3/0 (70-95 mm2) cables. Refer to S18737
tion. for instructions on installing these plugs.
b) Connect the LN-7 control cable to the wire feeder Use the shortest possible cable lengths. See Table
receptacle on the CV-300. A.1 for recommended cable sizes based on length.
c) See OUTPUT CONNECTIONS for connection of Connect the positive output lead to the terminal
work and electrode cables. marked "+". The negative output lead can be hooked
to either the low inductance terminal (marked "
LN-25 to CV-300 ") or the high inductance terminal (marked
" ").
a) Turn the CV-300 Power switch to the "OFF" posi-
TABLE A.1
tion.
Cable Sizes for Combined Lengths of Copper
Electrode and Work Cable
b) Plug a K484 jumper plug into the CV-300 wire
feeder receptacle. Lengths up to
Machine Size 150 ft 150 to 200 ft
300 A 100%
c) See OUTPUT CONNECTIONS for connection of 2/0 (70mm2) 3/0 (95mm2)
(400 A 60%)
work and electrode cables.
WARNING
The output terminals are energized at all times when
the K484 is plugged in.
------------------------------------------------------------------------
LN-742 to CV-300
a) Turn the CV-300 Power switch to the "OFF" posi-
tion.
b) Connect the LN-742 control cable to the wire
feeder receptacle on the CV-300.
c) See OUTPUT CONNECTIONS for connection of
work and electrode cables.
CV-300
A-4 A-4
INSTALLATION
PARALLELING
The CV-300 is not designed to be paralleled with any
other power source.
CONNECTION OF AUXILIARY EQUIPMENT
TO THE WIRE FEEDER RECEPTACLE
Occasionally, it may be necessary to make connection
to the circuits present in the 14-pin wire feeder recep-
tacle. 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-300 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-
300 and the wire feeder WITHOUT the need
for a K867 Universal Adapter.
CV-300
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section before oper-
ating the machine.
GENERAL WARNINGS
SAFETY PRECAUTIONS
WARNING
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.
� 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 away.
� Do not weld on containers that
have held combustibles.
ARC RAYS
can burn.
� Wear eye, ear and body
protection.
Observe additional Safety Guidelines detailed
throughout this manual.
CV-300
B-2 B-2
OPERATION
� Circuit breaker protected.
CAUTION
� 115 VAC, 5 amp auxiliary power available for the
wire feeder; circuit breaker protected.
When using a CV-300 power source with wire feed-
ers, there will be a small spark if the electrode con-
� Magnum Twist-Mate� output receptacles.
tacts the work or ground within several seconds after
releasing the trigger.
� Single MS-type (14-pin) connection for wire feeder.
When used with some wire feeders with the electrical
� Solid state controls, with line voltage compensation.
trigger interlock in the ON position, the arc might
restart if the electrode touches the work or ground
� Optional remote control capability.
during these several seconds.
------------------------------------------------------------------------
DESIGN FEATURES
GENERAL DESCRIPTION � "Clean" appearance and simple controls -- easy to
operate.
The CV-300 is a constant voltage DC power source
� Electronic and thermostatic protection from over-
designed for the GMAW process with limited FCAW
loads.
capability as well. It features an industrial rating of
300 amps, 32 volts, at 100% duty cycle. It complies
� Submersion dipping of assembled transformer,
with the requirements for a NEMA Class I (100) power
choke, and rectifier in special sealing/insulating
source.
material gives extra protection against moisture and
corrosive atmospheres.
It is available from the factory in one model only, with
no options other than input voltage or frequency.
� Microprocessor based Control PC Board has built-in
diagnostic routines.
RECOMMENDED PROCESSES AND
EQUIPMENT � Compact size, requires only 19" x 26" footprint.
The CV-300 is capable of solid wire welding within the � Modular construction for easy servicing.
rated output capacity of the machine. It is also capa-
ble of welding with the following flux-cored wires: NR-
� Recessed panels protect output studs and controls.
152, NR-211, NS-3M, NR-203 Ni 1%, and
Large safety margins and protective circuits protect
Outershield® 70 and 71.
rectifiers from transient voltages and high currents.
The CV-300 is recommended for use with the LN-7,
LIMITATIONS
LN-742 and LN-25 wire feeder models.
The CV-300 is intended only for use with the following
OPERATIONAL FEATURES AND
FCAW electrodes: NR-152, NR-211, NR-203 Ni 1%,
CONTROLS NS-3M, Outershield 70 and 71. The machine has
been designed primarily for the GMAW process.
� Two inductance positions: operator can choose the
optimum output characteristics. POWER SOURCE OPERATION
� Solid State Output Contactor: no noise, no moving
Be sure the CV-300 is properly installed, and that all
parts to wear.
accessories are properly hooked up before attempting
operation.
� Digital Voltmeter/Ammeter is standard.
DUTY CYCLE
� Power on/off switch.
300 Amps, 32 Volts at 100%
� 42 VAC, 10 amp auxiliary power available for the
400 Amps, 36 Volts at 60%
wire feeder.
Duty Cycle is based on operation for a 10 minute period.
CV-300
B-3 B-3
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the CV-300. Refer to Figures B.1, and B.2
and corresponding explanations.
FIGURE B.1 - CONTROL PANEL
D
E C
A
H J
B
G
F
A. POWER SWITCH F. 42 VOLT CIRCUIT BREAKER
B. VOLTAGE ADJUSTMENT G. 115 VOLT CIRCUIT BREAKER
C. THERMAL PROTECTION INDICATION LIGHT H. LOCAL / REMOTE SWITCH
D. VOLTS / AMPS SWITCH J. WIRE FEEDER VOLTMETER SWITCH
E. DIGITAL VOLTMETER / AMMETER
A. POWER SWITCH NOTE: Due to voltage drops in the welding cables
and at cable connection points, the actual arc
- A two-position toggle switch.Controls the voltage may be lower than that displayed on
input power to the CV-300. the voltmeter. Use welding cables of the
proper capacity and make sure all connec-
B. VOLTAGE ADJUST tions are tight to minimize this effect.
- Controls the CV-300 output voltage. F. 42 VOLT CIRCUIT BREAKER
C. THERMAL PROTECTION INDICATION LIGHT -Protects the 42 volt 41-42 circuit in the wire
feeder receptacle from overloads and shorts.
- Indicates that the protection thermostat has If this circuit breaker opens, the CV-300 will
activated. The digital meter will display "E10" work normally. However, any equipment
when this occurs. When the light turns off, powered by the 42 volt circuit will not work.
the machine will be capable of supplying
welding output power again. G. 115 VOLT CIRCUIT BREAKER
NOTE: Leaving the power switch in the "ON" posi- -Protects the 115 volt 31-32 circuit in the wire
tion will result in the most rapid cooling. feeder receptacle from overloads and shorts.
If this circuit breaker opens, the CV-300 will
D. VOLTS/AMPS SWITCH work normally. However, any equipment
powered by the 115 volt circuit will not work.
- Selects either output current or arc voltage
to be displayed on the digital meter. H. LOCAL/REMOTE SWITCH
E. DIGITAL VOLTMETER/AMMETER -Determines whether the welding voltage is
controlled at the CV-300, or controlled
- Displays the CV-300 output current, or the remotely by a remote output control (such as
arc voltage. a K857).
CV-300
B-4 B-4
OPERATION
-When welding electrode negative (most
J. WIRE FEEDER VOLTMETER SWITCH
Innershield electrodes) set the switch to "-".
-This switch selects the polarity of the wire
-This switch has no effect on the welding
feeder voltmeter, if so equipped. When weld-
polarity. In fact, if the wire feeder being used
ing electrode positive (MIG, Outershield and
does not have a voltmeter, the setting of this
some Innershield processes) set the switch
switch has no effect.
to "+".
GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL
THERMAL PROTEC-
TION INDICATOR
OFF
LIGHT
CIRCUIT
ON
BREAKER
CLOCKWISE ROTA-
AC
TION INCREASES
POWER
VOLTAGE
REMOTE OUTPUT LOCAL OUTPUT
VOLTAGE CONTROL VOLTAGE CONTROL
INDICATES WARNING INFORMATION
WARNING
LOCATED ON RIGHT CASE SIDE
CV-300
B-5 B-5
OPERATION
OUTPUT PANEL CONNECTIONS
FIGURE B.2 - OUTPUT PANEL
D
C
B
A
A. POSITIVE OUTPUT CONNECTION C. HIGH INDUCTANCE NEG. CONNECTION
B. LOW INDUCTANCE NEG. CONNECTION D. WIRE FEEDER RECEPTACLE
A., B., C. OUTPUT CONNECTORS C. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION.
-Each connector is a Magnum Twist-Mateâ„?, -The high inductance connection is more suit-
receptacle. Insert a mating Twist-Mateâ„? able for short arc welding heavier weldments
plug, and twist clockwise to secure. or when using 75% Argon/25% CO2 shield-
ing gas. This connection produces a softer
For GMAW processes, and most FCAW arc and a flatter bead with more wash-in than
processes, the positive output connection the low inductance connection. A spray type
goes to the wire feeder. One of the negative transfer is possible with either connection.
output connections goes directly to the work.
A. POSITIVE OUTPUT CONNECTION. D. WIRE FEEDER RECEPTACLE
-14-pin MS style receptacle for wire feeder.
B. LOW INDUCTANCE NEGATIVE CONNECTION. Provides connections for auxiliary power,
contactor closure, remote output control, wire
-The low inductance connection is typically feeder voltmeter sense lead, and ground.
used for short arc welding of mild steel, par-
ticularly on thin materials or when using CO2
shielding gas.
CV-300
B-6 B-6
OPERATION
STARTING THE MACHINE AUXILIARY POWER
The power switch at the extreme right side of the con- 42 volt AC auxiliary power, as required for some wire
trol panel energizes the CV-300. feeders, is available through the wire feeder recepta-
cle. A 10 amp circuit breaker protects the 42 volt cir-
cuit from overloads.
ADJUSTING THE OUTPUT VOLTAGE
USING THE DIGITAL METER CV-300 machines can also supply 115 volt AC auxil-
iary power through the wire feeder receptacle. A 5
The digital meters in the CV-300 incorporate a voltage pre- amp circuit breaker protects the 115 volt circuit from
set function. This allows the operator to set the desired overloads.
welding voltage before striking an arc. The digital meters
can also display welding current. NOTE: Do not use circuits 2 or 4 for control of auxil-
iary loads. (The 2-4 circuit is isolated from the
To make use of the voltage preset function, the Volts/Amps 31-32 and 41-42 circuits.)
switch must be in the "Volts" position. Turn the Voltage
Adjust knob until the digital meter displays the desired weld-
CAUTION
ing voltage. (See below if an external power source remote
control is installed.)
Note that some types of equipment, especially pumps
When an arc is struck, the digital meter displays the actual and large motors, have starting currents which are
welding voltage, as measured at the CV-300 output termi- significantly higher than their running current. These
nals. higher starting currents may cause the circuit breaker
to open. If this situation occurs, the user should refrain
NOTE: The arc voltage at the electrode may be as much as from using the CV-300 auxiliary power for that equip-
two volts different from the CV-300 output terminal ment.
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-
OVERLOAD PROTECTION
quate capacity, and make sure all connections are
clean and tight. Because of these voltage drops, This welder has thermostatic protection from exces-
you may have to preset the CV-300 for a slightly sive duty cycles, overloads, loss of cooling, and high
higher welding voltage than your procedure calls for. ambient temperatures. When the welder is subjected
to an overload or loss of cooling, a thermostat will
To read welding current, set the Volts/Amps switch to the open. This condition will be indicated by the illumina-
"Amps" position. The welding current will be displayed tion of the yellow Thermostatic Protection Light on the
whenever an arc is struck. case front (see Figure B.1).The fan will continue to run
to cool the power source. No welding is possible until
LOCAL/REMOTE SWITCH OPERATION the machine is allowed to cool and the Thermostatic
Protection Light goes out.
If voltage control is desired at the CV-300, the Local/Remote
switch must be in the "Local" position. The Voltage Adjust
on the front panel can be used to adjust the CV-300 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 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-300 output.
CV-300
C-1 C-1
ACCESSORIES
FACTORY INSTALLED COMPATIBLE LINCOLN EQUIPMENT
OPTIONS/ACCESSORIES
The CV-300 is intended for use with the LN-7, LN-742,
and LN-25 wire feed units. Use the Cables / Kits listed
There are no factory installed options/accessories on
below to make connection easily:
the CV-300.
LN-7 / LN-7GMA Requires K480 Input Cable
FIELD INSTALLED OPTIONS
LN-25 Requires K484 Jumper Plug Kit
REMOTE VOLTAGE CONTROL (K857)
LN-25 w/K444-1 Requires K864 Remote Control
The K857 consists of a control box with 25 feet (7.6 Remote Voltage Adapter and K484 Jumper Plug
m) of four conductor cable. Installation of a K857 Control Kit Kit
Remote Voltage Control in the CV-300 requires a
K864 Remote Control Adapter. Refer to the instruc- LN-742 / LN-742H Requires K591 Input Cable
tions provided with the K857 for hookup to the CV-
300. When properly connected, and with the CV-300
Local-Remote Switch in the "Remote" position, the
K857 functions the same as the CV-300 Voltage
Adjust control, enabling minimum to maximum output
voltage adjustment of the CV-300.
UNDERCARRIAGE (K835)
Includes front casters, a handle, a bracket, and a rear
wheeled platform that is capable of carrying one gas
cylinder. The CV-300 lifting eye is not functional with
the K835 undercarriage installed.
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-300 lifting eye is not
functional when the K874 undercarriage is installed.
WIRE FEEDER SWIVEL MOUNT (K178-1)
Allows an LN-7 or LN-742 to be securely mounted on
the roof of a CV-300.
UNIVERSAL ADAPTER (K867)
Provides a means of connecting auxiliary equipment
to the wire feeder receptacle on the CV-300 power
source. Consists of a 14-pin MS-type (Amphenol)
plug with 8 inch (0.2 meter) long flex leads, one 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.
CV-300
D-1 D-1
MAINTENANCE
SAFETY PRECAUTIONS MACHINE AND CIRCUIT PROTECTION
WARNING The CV-300 Control PC Board has built-in diagnostic
routines to alert the operator when trouble exists.
ELECTRIC SHOCK can kill.
When a trouble condition occurs, the CV-300 meter
will display an error code, in the form "EXX", where
� Only qualified personnel should
"XX" refers to a specific error. See TROU-
perform this maintenance.
BLESHOOTING section for an explanation of the error
codes.
� Turn the input power OFF at the
disconnect switch or fuse box
The power source is thermostatically protected
before working on this
against overload or insufficient cooling. If the machine
equipment.
is overloaded, the thermostat will open, thermal pro-
tection indicator light will turn on, and the output will
� Do not touch electrically hot
be zero. The fan will continue to run and auxiliary
parts.
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.
GENERAL MAINTENANCE
The CV-300 is electronically protected against over-
1. The fan motor has sealed bearings which require loads and accidental short circuits. The overload pro-
no service. tection circuit automatically reduces the output current
to a safe value when an overload is detected. If the
2. In extremely dusty locations, dirt may clog the air circuitry senses a short circuit, it will shut off the CV-
channels causing the welder to run hot with prema- 300 output. The short circuit protection circuit can be
ture tripping of thermal protection. Blow out the reset by turning the CV-300 Power switch OFF for at
welder with low pressure air at regular intervals to least 10 seconds. Remove the short before turning
eliminate excessive dirt and dust build-up on inter- the Power switch ON again.
nal parts.
CV-300
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
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.
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-300
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
BUILT-IN DIAGNOSTIC ROUTINES AND ERROR CODES
The CV-300 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
E00 1. Output short circuited. 1. Turn power off. Remove short circuit.
2. 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.
E10 Thermostat circuit has opened. Allow machine to cool. Be sure to provide adequate
ventilation for machine.
E20 Memory error. See PC Board Troubleshooting Procedure.
E30 1. Voltage Adjust potentiometer not 1. Check wiring between Voltage Adjust and the
connected. Control PC Board.
2. Remote Control not functioning 2. See Options Troubleshooting Guide.
correctly.
E40 Input line voltage too low. Turn power off. Insure machine input voltage is within
specifications. Turn power back on.
E50 Input line voltage too high. Turn power off. Insure machine input voltage is within
specifications. Turn power back on.
E60 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 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-300
E-3 E-3
TROUBLESHOOTING
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 AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION
PROBLEMS
Machine has no output. 1. Secondary contactor circuit (2
and 4 wire feeder receptacle) not
working.
2. Electrode or work lead loose or
broken.
3. Defective PC Board.
4. Protective circuits operating due
to output short circuit.
5. If using an LN-25, K484 jumper
plug kit not making connection
between 2 & 4 in wire feeder
receptacle.
6. If welding with 1/16" aluminum
wire and machine is flashing E00. 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 and no 1. Voltage Control misconnected.
control.
Machine has low output and no con- 1. Open in feedback circuitry.
trol.
2. Faulty PC Board.
3. Voltage Adjust potentiometer
circuit open (lead 75).
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-300
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION
PROBLEMS
Thermal Protection Indicator light is 1. Thermostat circuit has opened.
on.
2. Faulty Control PC Board.
Machine does not have maximum 1. Faulty Control PC Board.
output
2. Voltage Adjust potentiometer
defective.
3. Voltage Adjust potentiometer
leads open.
Machine will not shut off. 1. Defective power switch.
Variable or sluggish welding arc. 1. Poor work or electrode If all recommended possible areas
connection. of misadjustment have been
checked and the problem persists,
2. Welding leads too small. Contact your local Lincoln
Authorized Field Service Facility.
3. Welding current or voltage
too low.
4. Defective SCR bridge.
Digital meters do not light 1. Faulty Meter PC board.
- or -
Digital meter display is incorrect.
2. 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-300
E-5 E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION
PROBLEMS
Output Control not functioning on the 1. Local/Remote switch is in
machine. the "Remote" position.
2. Faulty Voltage Adjust
potentiometer.
3. Leads or connections open in
control circuit.
4. Malfunctioning Remote Control.
5. Faulty Control PC board.
Poor arc striking with semiautomatic 1. Poor work connection.
wire feeders.
2. Improper procedures.
3. Wire feed acceleration too fast or If all recommended possible areas
too slow. of misadjustment have been
checked and the problem persists,
4. Defective PC Board. Contact your local Lincoln
Authorized Field Service Facility.
Poor arc characteristics 1. 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-300
E-6 E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
OPTIONS TROUBLESHOOTING GUIDE
K857 (or other) Remote Output Control
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENTS COURSE OF ACTION
PROBLEMS
Output control not functioning on 1. Local/Remote switch in wrong
Remote Control. position.
2. Faulty Local/Remote switch.
3. Faulty Remote Control poten-
tiometer.
4. Leads or connections open in
control circuit.
5. Faulty Control PC board.
Voltage Adjust not functioning on the 1. Local/Remote switch in the If all recommended possible areas
machine. wrong position. of misadjustment have been
checked and the problem persists,
2. Faulty Local/Remote switch. Contact your local Lincoln
Authorized Field Service Facility.
3. Faulty Voltage Adjust
potentiometer.
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-300
E-7 E-7
TROUBLESHOOTING
Procedure for Replacing PC Boards PC BOARD TROUBLESHOOTING
PROCEDURES
WARNING
CONTROL PC BOARD
ELECTRIC SHOCK can kill.
� Have a qualified individual install and
The Control PC Board controls all machine functions
service this equipment.
including the thermal protection indicator light and the
� Turn the power source input power off
Meter PC Board. Most problems, if not caused by
at the disconnect switch before work-
faulty wiring machine misuse, will stem from a faulty
ing on this equipment.
Control PC Board.
� Do not touch electrically hot parts.
---------------------------------------------------------------------
Perform the following diagnostic procedure before
replacing the Control PC Board.
Before replacing a PC board which is suspected of
being defective, visually inspect the PC board in ques-
1. Turn off the input power at the fuse box.
tion for any electrical or mechanical damage to any of
its components and conductors on the back of the
2. Check for loose connections in the PC Board
board.
plugs, particularly J3.
a. If there is no visible damage to the PC board,
3. Disconnect the J3 plug from the Control PC Board.
install a new one and see if this remedies the prob-
Measure the resistance between the following wire
lem. If the problem is remedied, reinstall the old
terminals in the plug:
PC board to see if the problem still exists. If it
does no longer exist with old PC board:
A) Between wire #200 and wire #201.
1. Check the PC board harness connector pins for
B) Between wire #202 and wire #203.
corrosion, contamination, or looseness.
Both of these resistances should be less than 1 ohm.
2. Check leads in the plug harness for loose or
intermittent connection.
If these resistances are not less than 1 ohm, check the
wiring back to the main transformer.
b. If PC board is visibly damaged electrically, before
possibly subjecting the new PC board to the same
If these voltages are less than 1 ohm, refer to
cause of failure, check for possible shorts, opens,
"Procedure for Replacing PC Boards."
or grounds caused by:
METER PC BOARD
1. Frayed or pinched lead insulation.
2. Poor lead termination, such as a poor contact When the Meter PC Board malfunctions, first determine
or a short to adjacent connection or surface. if the rest of the machine functions correctly. If so, then
the problem is in either the harness between the meter
3. Shorted or open motor leads, or other external and control boards, or in the meter board itself. Refer
leads. to "Procedure for Replacing PC Boards". As a last
resort, the Control PC Board may have to be replaced.
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.
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-300
E-8 E-8
TROUBLESHOOTING
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-300 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-300 power switch must be turned
"OFF" and then "ON" to return the machine to normal
output.
CHECKING SNUBBER CIRCUIT
In case of an SCR malfunction or failure, the snubber
assembly should be checked. Disconnect the input
power to the CV-300 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-300
F-1
WIRING DIAGRAM CV-300 (60Hz)
SNUBBER/BYPASS
P.C. BOARD
8
204C
2
221
3 SCR3
RECONNECT 204D
223 222 3
PANEL J5
INPUT SUPPLY 6
223 213
4
7.5 OHM
LINES J5
3 1
224
220 W 213
214
5
G3
D3 7 400 A. 50mV
R1
C SHUNT
U V W
+
224A -
6 +
SCR2 213A
9
L1 L2 L3 213B
N.B.
F
+
12 2 G2 -
C1
D2
222
+
1 2 3 L1 CHOKE
218
2 C2 213B 214
+
B -
204D C3 214B
224B
S1
5 204C +
LINE
8
SWITCH C4
SCR1
204A
E
213A
11 219
LOCAL/REMOTE SWITCH
224A
1 214A
CONTROL (SHOWN IN LOCAL POSITION)
G1
1 221 D4
D5 P. C. BOARD 376
D1 S4
A
* 1
377
J10
4 S3
2 277
224B
224
7
21 WIRE FEEDER
D VOLTMETER
276
G2 4 77 SWITCH
10
J1
2
G3 76
214B
8
204A 1 224B
3
377
G1 3 277
7
376
TO A SYSTEM GROUND PER
N.A.
* 213B 4
NATIONAL ELECTRICAL CODE.
s CW
202 276
8 4 WIRE FEEDER
77 H
10K
J2 VOLTMETER
12V O2 TOP
R2
OUTPUT E
76
9
203 NC
2 CONTROL
F
s
200 6
G
75
275
5
208/230/460 INPUT VOLTAGES 12V O1 TOP
31 2 2 C
1
J3
201 10
4 4 D
RECONNECT RECONNECT RECONNECT 6
CV-300
208V 230V 460V 2
SECONDARY
s
PANEL PANEL PANEL 215 N
41
41A
THERMOSTAT 3
31
1
207
6 J
4
6 5
4 4
5 5
6 6
C C C 205 7
42V O1 TOP 115 VAC
L1 32
2
1 208 A
B B B 5
206 J7
8 8 8
7 7 7
9 9 9
41
209
42 3
42A 4 I
DIAGRAMS
METER
NC 1 42 VAC
2 2 2 CB1
3 1 3 1 3 1 42
J4 210 4 K
3
10A P.C.
A A A
L
CIRCUIT BOARD
BREAKER
s
D D
F F D F
E E E 211 B GROUND
5
S2
212
2 M
3 2 1 3 2 1 3 2 1 N.A.
VOLTS / AMPS
O3 TOP
58V
WIRE
(SHOWN IN "VOLTS" POSITION)
TO S1 LINE SWITCH TO S1 LINE SWITCH TO S1 LINE SWITCH
FEEDER
32
33
RECEPTACLE
CB2
230/460/575 INPUT VOLTAGES 33A 5A
ELECTRICAL SYMBOLS
CIRCUIT
CUSTOMER
RECONNECT RECONNECT RECONNECT PER E1537
BREAKER
230V 460V 575V
CONNECTIONS
PANEL PANEL PANEL FAN
115V
8
8
8
8 8 8
9 9 9
7 7 7 CONNECTOR CAVITY NUMBERING SEQUENCE
O3 BOT.
58V
31A (COMPONENT SIDE OF P. C. BOARD)
6 6 6
4 4 4
31
31B
5 5 5 s
F E F E F E
D D D
3 2 1 3 2 1 3 2 1
8 PIN 10 PIN
2 PIN 4 PIN 6 PIN
J10 J1 J2 J3
J4
3 2 1 3 2 1 3 2 1
J7 J5
TO S1 LINE SWITCH TO S1 LINE SWITCH TO S1 LINE SWITCH
C1-C4 31,000 MFD EACH
N.A. WIRING VIEWED FROM REAR OF POTENTIOMETER
MAIN TRANSFORMER
N.B. TAP LEADS A, B, AND C APPEAR ON THE TOP PRIMARY COILS
OF 208/230/460V MACHINES ONLY.
6-18-93
L8927
CLEVELAND, OHIO U.S.A.
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..
F-1
F-2
WARNING
Turn off input power to the Welding Power Source
using the disconnect switch at the fuse box
Before connecting the wire feeder.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
14 PIN
CV/CV-I AMPHENOL
OPTIONAL K857
POWER SOURCE
REMOTE CONTROL
N.C. LN-7/LN-7GMA
CV-300
WIRE
FEEDER
DIAGRAMS
+ - OPTIONAL K864 REMOTE
CONTROL ADAPTER
K480 INPUT CABLE ASSEMBLY
CV POWER SOURCE TO AN LN-7 AND K857
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
6-18-93
N.C. USE OF THE K857 REMOTE CONTROL REQUIRES THE INSTALLATION OF A K864 REMOTE
S20662
CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE.
F-2
F-3
WARNING
Turn off input power to the Welding Power Source
using the disconnect switch at the fuse box
Before connecting the wire feeder.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL N.C.
81
CV/CV-I
NOT USED ON CV/CV-I POWER SOURCES
82
POWER SOURCE SPARE
2 CONNECT TOGETHER FOR
14 PIN
N.D.
4
AMPHENOL WELDING OUTPUT
41
42 VAC
K867 UNIVERSAL 42
N.E.
ADAPTER PLUG
31
115 VAC N.F.
32
+ -
POWER SOURCE FRAME CONNECTION
GND
CV-300
21 WIRE FEEDER VOLTMETER CONNECTION
DIAGRAMS
CONNECTS TO (WORK TERMINAL) OF POWER SOURCE
77 10K
TO WORK
76 REMOTE OUTPUT CONTROL
ELECTRODE CABLE 75 N.F.
MIN.
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
TO
2
CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER
N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION TO
WIRE
{
RELAY TO CLOSE LEADS 2 & 4. K867
FEEDER
4
N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY
CURRENT DRAW.
6-18-93
N.F. NOT PRESENT ON ALL MACHINES S20658
F-3
F-4
WARNING
Turn off input power to the Welding Power Source
using the disconnect switch at the fuse box
Before connecting the wire feeder.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
CV/CV-I
SPARE
POWER SOURCE
82 LN-7
14 PIN
81 N.C. WIRE
AMPHENOL
FEEDER
42
41
31 31
+ -
32 32
2 2
CV-300
4 4
21 21
DIAGRAMS
K291 OR K404
K867 UNIVERSAL
GND GND INPUT CABLE
ADAPTER PLUG
TO WORK GREEN
75
75
ELECTRODE CABLE
76 76
77 77
K775 OPTIONAL
CV POWER SOURCE TO A K867 / K775 / LN-7
N.D. REMOTE CONTROL
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. 6-18-93
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
S20659
REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.
F-4
F-5
WARNING
Turn off input power to the Welding Power Source
using the disconnect switch at the fuse box
Before connecting the wire feeder.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
OPTIONAL K857
CV/CV-I 14 PIN
REMOTE CONTROL
AMPHENOL
POWER SOURCE
N.C.
OPTIONAL K864 REMOTE
+ CONTROL ADAPTER
-
OPTIONAL
LN-25
K484 JUMPER
WIRE FEEDER
CV-300
PLUG
N.D.
DIAGRAMS
TO WORK
ELECTRODE CABLE
CV POWER SOURCE TO AN LN-25
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.
N.C. USE OF THE K857 REMOTE CONTROL REQUIRES INSTALLATION OF A K864 REMOTE
CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE.
N.D. CONNECT THE K484 JUMPER PLUG DIRECTLY TO THE 14 PIN AMPHENOL
OF THE POWER SOURCE IF NO REMOTE CONTROL IS USED.
IF USING A K857 REMOTE CONTROL,CONNECT THE K484 JUMPER PLUG
6-18-93
TO THE 14 PIN AMPHENOL OF THE K864 REMOTE CONTROL ADAPTER.
S20661
THE POWER SOURCE WELDING TERMINALS ARE ALWAYS "HOT" WHEN THE K484 JUMPER
F-5
F-6
CV/CV-I POWER SOURCE TO LN-25 WITH K444-1 OPTION CONNECTION DIAGRAM
WARNING
Turn off input power to the Welding Power Source
using the disconnect switch at the fuse box
Before connecting the wire feeder.
Only qualified persons should install, use or
ELECTRIC
SHOCK service this machine.
CAN KILL
CV/CV-I 14 PIN
AMPHENOL
POWER SOURCE
OPTIONAL K864 REMOTE
N.D.
CONTROL ADAPTER
+ -
LN-25
N.C.
WIRE FEEDER
CV-300
WITH K444-1 OPTION
OPTIONAL
K484 JUMPER
DIAGRAMS
TO WORK PLUG
ELECTRODE CABLE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",
CV POWER SOURCE TO AN LN-25 / K444-1
REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.
N.C. CONNECT THE K484 JUMPER PLUG TO THE 14 PIN RECEPTACLE OF THE
K864 REMOTE CONTROL ADAPTER. CONNECT THE 6 PIN PLUG FROM THE
LN-25 (WITH K444-1 OPTION) TO THE 6 PIN RECEPTACLE OF THE K864
REMOTE CONTROL ADAPTER. SWITCH THE POWER SOURCE "LOCAL/REMOTE" SWITCH TO REMOTE.
N.D. THE POWER SOURCE TERMINALS ARE ALWAYS "HOT" WHEN THE K484 JUMPER
PLUG KIT IS INSTALLED.
6-18-93
S20663
CLEVELAND, OHIO U.S.A.
F-6
F-7
WARNING
Turn off (0) the power switch on the Welding
Power Source before connecting the wire feeder.
LINCOLN
Only qualified persons should install, use or
POWER SOURCE
N.D.
service this machine.
ELECTRIC
14 PIN SHOCK
CAN KILL
AMPHENOL
LN-742
WIRE
N.A. WELDING CABLE MUST BE SIZED FOR CURRENT
FEEDER
AND DUTY CYCLE OF APPLICATION.
+ -
N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO
CHANGE POLARITY, TURN POWER "OFF",
REVERSE ELECTRODE AND WORK CABLES AT
POWER SOURCE AND SET WIRE FEEDER
VOLTMETER POLARITY SWITCH ON POWER
SOURCE TO PROPER POLARITY.
TO WORK
LN-742
N.C. PINS NOT LISTED ARE NOT CONNECTED
INPUT CABLE
ELECTRODE CABLE
ON CABLE.
ASSEMBLY
CV-300
N.D. IF USING K589-1, REMOTE CONTROL KIT,
SET POWER SOURCE CONTROL SWITCH
DIAGRAMS
TO "REMOTE" POSITION.
FUNCTIONS ARE LISTED FOR REFERENCE K=42
K=42
ONLY AND EACH MAY OR MAY NOT BE
PRESENT IN YOUR EQUIPMENT.
I=41
(SEE APPROPRIATE WIRING DIAGRAM)
I=41
FUNCTION
PIN LEAD
LINCOLN POWER SOURCE TO AN LN-742
C=2
H=21
2 TRIGGER CIRCUIT
C
4
D TRIGGER CIRCUIT C=2 H=21
1-28-94
E 77 OUTPUT CONTROL
S20409
76
F D=4
G=75
OUTPUT CONTROL
D=4 G=75
75
G OUTPUT CONTROL
F=76 E=77
E=77 F=76
21
H WORK
14-SOCKET BOX RECEPTACLE, FRONT VIEW 14-SOCKET BOX RECEPTACLE, REAR VIEW
41 42V AC
I
AND 14-PIN CABLE PLUG, FRONT VIEW
AND 14-PIN CABLE PLUG, REAR VIEW
42 42V AC
K
F-7
F-8
INSTALLATION INSTRUCTIONS
THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN
WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS
TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.
CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.
NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.
1. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING
THIS ADAPTER TO WIRE FEEDER CABLE.
2. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.
THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.
NOTE: 115V AC (31, 32), 42V AC (41, 42), 24V AC (SPARE) AND TRIGGER CIRCUIT (2, 4)
MAY OR MAY NOT BE ISOLATED, INDEPENDENT CIRCUITS INSIDE THE WELDER.
3. USE LUG, CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD
IN THE UNIVERSAL ADAPTER. THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.
(SEE APPROPRIATE WIRING DIAGRAM)
THESE FUNCTIONS ARE LISTED FOR
K=42 K=42
REFERENCE ONLY AND EACH MAY OR
CV-300
MAY NOT BE PRESENT IN YOUR EQUIPMENT. J=31
A=32 J=31 A=32
STANDARD FUNCTION
PIN LEAD
I=41
B=GND
DIAGRAMS
I=41 B=GND
115V AC
32
A
L=82 N=SPARE
CHASSIS CONNECTION
GND
B
C=2
H=21
TRIGGER CIRCUIT
2
C
4 TRIGGER CIRCUIT
D H=21
C=2 L=82
N=SPARE
E 77 OUTPUT CONTROL
76
F D=4
OUTPUT CONTROL G=75
D=4 G=75
75
G OUTPUT CONTROL
E=77
F=76 F=76
E=77
21
H WORK
M=81
M=81
42V AC
41
I
J 115V AC
31 14-PIN BOX RECEPTACLE, REAR VIEW
14-PIN BOX RECEPTACLE, FRONT VIEW
42V AC
42
K
AND 14-PIN CABLE PLUG, FRONT VIEW
AND 14-PIN CABLE PLUG, REAR VIEW
WELDING MODE CONTROL
82
L
3-16-90
M 81 WELDING MODE CONTROL
S19386
N SPARE 24V AC
K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS
F-8
F-9 F-9
DIAGRAMS
TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS
TWIST-MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS
TURN THE POWER SWITCH OF THE WELDING POWER
SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO
WELDING POWER SOURCE.
CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE
1.
APPROPRIATE CABLE SIZE PER TABLE BELOW; AND
SKIN CABLE JACKET TO LENGTH SPECIFIED:
AMERICAN (EUROPEAN) RANGE CABLE SKIN LENGTH
BOOT MARKING
CABLE SIZE
2
1 INCH (25.4mm)
mm )
35-50 #2-#1 ( 35-50
2
1 INCH (25.4mm)
mm )
50-70 1/0-2/0 ( 50-70
2
2/0-3/0 1.5 INCH (38.1mm)
70-95 mm )
( 70-95
If necessary, trim cable end of boot at groove(s) to match cable
2.
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.
BOOT
Slide rubber boot onto cable end.
3.
WELDING CABLE
SEE
ABOVE
TRIM
Slide the copper tube into the brass plug.
4. SET SCREW
(70-95 size may
Insert cable into copper tube.
5.
have 2 set
screws)
BRASS PLUG
COPPER TUBE
9-20-91J
Tighten set screw(s) to collapse copper tube. Screw(s)
6.
must apply firm pressure against welding cable. The top of the
set screw(s) will be nearly flush or below the surface of the
S18737
brass plug after tightening.
Slide rubber boot over brass plug. The rubber boot must be
7.
positioned to completely cover all electrical surfaces after
the plug is locked into the receptacle.
CV-300
F-10 F-10
DIAGRAMS
CONNECTION OF NON-LINCOLN WIRE FEEDERS
CV-300
F-11
41.58 (1056)
26.00 (660) 11.99 (304)
20.05 (509)
19.65 (499) 3.90 (99)
12.60 (320)
3.61 (91)
19.20 (487) .28
(7.0)
1.68
(42.7)
N.B.
24.75
(628)
CV-300
21.50 (546)
DIAGRAMS
30.95
DIMENSION PRINT
(786)
N.A.
N.A.
6.20 (157)
17.25 (438) (CENTERED) 1.38 23.62 (600) 1.00 (25.4)
(35)
N.A. FOUR SLOTS IN BASE FOR MOUNTING
N.A.
5-18-90J
WELDER DOWN USING 5/16 SCREWS
M15665
N.B. HANDLE CONFIGURATION ON EARLIER MODELS.
F-11
NOTES
CV-300
NOTES
CV-300
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
since 1933, the Procedure Handbook is considered by many to such as distortion; and supplemental information on arc
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For details write: Lincoln Welding School
Symbols. Detailed discussion tells how engineers and
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G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 PRODUITS 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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� 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
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