Lincoln Electric CV 425 User manual

IM3033

09/2016

REV02

CV 425 & 510

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

www.lincolnelectric.eu

English I English

Declaration of conformity

Lincoln Electric Bester Sp. z o.o.

Declares that the welding machine:

K14080-2A CV 425 AIR 220/380/440V

K14081-2A CV 510 AIR 220/380/440V

conforms to the following directives:

2014/35/EU, 2014/30/EU

and has been designed in compliance with the

following standards:

EN 60974-1:2012, EN 60974-10:2014

20.04.2016

Piotr Spytek

Operations Director

Lincoln Electric Bester Sp. z o.o., ul. Jana III Sobieskiego 19A, 58-263 Bielawa, Poland

12/05

English II English

12/05

THANKS! For having chosen the QUALITY of the Lincoln Electric products.

Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For future reference record in the table below your equipment identification information. Model Name, Code & Serial

Number can be found on the machine rating plate.

Model Name:

………………………………………………………………………………………………………………………………………….

Code & Serial Number:

………………………………………………………………….. …………………………………………………………………..

Date & Where Purchased

…………………………………………………………………. …………………………………………………………………..

ENGLISH INDEX

Safety.................................................................................................................................................................................. 1

Installation and Operator Instructions.................................................................................................................................. 2

Electromagnetic Compatibility (EMC).................................................................................................................................. 5

Technical Specifications...................................................................................................................................................... 6

WEEE ................................................................................................................................................................................. 7

Spare Parts ......................................................................................................................................................................... 7

Electrical Schematic............................................................................................................................................................ 7

Accessories......................................................................................................................................................................... 7

English 1 English

Safety

11/04

WARNING

This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair

procedures are performed only by qualified person. Read and understand this manual before operating this equipment.

Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this

equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible

for damages caused by improper installation, improper care or abnormal operation.

WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,

loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or

death.

READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating this

equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could cause

serious personal injury, loss of life, or damage to this equipment.

ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the

electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from the

electrode, work clamp and connected work pieces.

ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the

fuse box before working on this equipment. Ground this equipment in accordance with local electrical

regulations.

ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp

cables. If any insulation damage exists replace the cable immediately. Do not place the electrode holder

directly on the welding table or any other surface in contact with the work clamp to avoid the risk of

accidental arc ignition.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any

conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some pacemakers

and welders having a pacemaker shall consult their physician before operating this equipment.

CE COMPLIANCE: This equipment complies with the European Community Directives.

ARTIFICIAL OPTICAL RADIATION: According with the requirements in 2006/25/EC Directive and EN

12198 Standard, the equipment is a category 2. It makes mandatory the adoption of Personal Protective

Equipment (PPE) having filter with a protection degree up to a maximum of 15, as required by EN169

Standard.

FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to

health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use enough

ventilation or exhaust to keep fumes and gases away from the breathing zone.

ARC RAYS CAN BURN: 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. Use suitable clothing made from durable

flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel with

suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to the

arc.

WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding area

and have a fire extinguisher readily available. Welding sparks and hot materials from the welding

process can easily go through small cracks and openings to adjacent areas. Do not weld on any tanks,

drums, containers, or material until the proper steps have been taken to insure that no flammable or

toxic vapors will be present. Never operate this equipment when flammable gases, vapors or liquid

combustibles are present.

English 2 English

WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and

materials in work area can cause serious burns. Use gloves and pliers when touching or moving

materials in the work area.

CYLINDER MAY EXPLODE IF DAMAGED: Use only compressed gas cylinders containing the correct

shielding gas for the process used and properly operating regulators designed for the gas and pressure

used. Always keep cylinders in an upright position securely chained to a fixed support. Do not move or

transport gas cylinders with the protection cap removed. Do not allow the electrode, electrode holder,

work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders must be located

away from areas where they may be subjected to physical damage or the welding process including

sparks and heat sources.

SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in an

environment with increased hazard of electric shock.

The manufacturer reserves the right to make changes and/or improvements in design without upgrade at the same time

the operator’s manual.

Installation and Operator Instructions

Read this entire section before installation or operation

of the machine.

Location and Environment

This machine will operate in harsh environments.

However, it is important that simple preventative

measures are followed to assure long life and reliable

operation:

Do not place or operate this machine on a surface

with an incline greater than 15° from horizontal.

Do not use this machine for pipe thawing.

This machine must be located where there is free

circulation of clean air without restrictions for air

movement to and from the air vents. Do not cover

the machine with paper, cloth or rags when switched

on.

Dirt and dust that can be drawn into the machine

should be kept to a minimum.

This machine has a protection rating of IP23. Keep it

dry when possible and do not place it on wet ground

or in puddles.

Locate the machine away from radio controlled

machinery. Normal operation may adversely affect

the operation of nearby radio controlled machinery,

which may result in injury or equipment damage.

Read the section on electromagnetic compatibility in

this manual.

Do not operate in areas with an ambient temperature

greater than 40°C.

Duty cycle and Overheating

The duty cycle of a welding machine is the percentage of

time in a 10 minute cycle at which the welder can

operate the machine at rated welding current.

Example: 60% duty cycle

Welding for 6 minutes. Break for 4 minutes.

Excessive extension of the duty cycle will cause the

thermal protection circuit to activate.

Minutes or decrease

Duty Cycle

The machine is protected from overheating by a

temperature sensor.

Input Supply Connection

WARNING

Only a qualified electrician can connect the welding

machine to the supply network. Installation the outlet

plug to power lead and connecting the welding machine

had to be made in accordance with the appropriate

National Electrical Code and local regulations.

Check the input voltage, phase, and frequency supplied

to this machine before turning it on. Verify the

connection of grounding wires from the machine to the

input source. The allowable input voltages are 3x220V

50/60Hz, 3x380V 50/60Hz and 3x440V 50/60Hz

(3x440V: factory default). For more information about

input supply refer to the technical specification section of

this manual and to the rating plate of the machine.

If it is necessary to change the input voltage:

The input cable must be disconnected from the

mains supply and the machine switched OFF.

Remove the left side panel.

Reconnect X6 according to the diagram below:

220V 380V 440V

X6 X6 X6

Figure 1.

English 3 English

Replace the left side panel.

Make sure that the amount of mains power available

from the input supply is adequate for normal operation of

the machine. The necessary delayed fuse (or circuit

breaker with "D" characteristic) and cable sizes are

indicated in the technical specification section of this

manual.

Output Connections

Refer to points [4], [5], [6] and [8] of the Figures 2.

Controls and Operational Features

Figure 2.

1. Power Switch ON/OFF (I/O): Controls the input

power to the machine. Be sure the power source is

connected to the mains supply before turning power

on ("I").

2. Power Indicator Light: After input power

is connected and the power switch is

turned on, this lamp will light up to

indicate the machine is ready to weld.

3. Thermal Overload Indicator: This lamp

will light up when the machine is

overheated and the output has been

turned off. This can occur if the ambient

temperature is above 40°C or the duty cycle of the

machine has been exceeded. Leave the machine on

to allow the internal components to cool, when the

lamp turns off normal operation is possible.

4. Low Inductance Negative Output Socket:

For connecting a work lead.

5. High Inductance Negative Output

Socket: For connecting a work lead.

6. Wire Feeder Receptacle: 14-pins

receptacle for wire feeder. Provides

connections for auxiliary power of wire

feeder.

7. Wire Feeder Voltmeter Switch: This

switch selects the polarity of the wire

feeder voltmeter, if so equipped. When the welding

torch is positive (MIG, Outershield and some

Innershield processes), set the switch to "+". When

the welding torch is negative (most Innershield

applications), set the switch to "-".

8. Positive Output Socket: Allows the

connection, with the power cable, to the

wire feeder.

9. Digital Welding Current and Voltage Meter: available

as an option (see "Accessories" chapter – Kit

K14082-1).

11 12

CV 425

11 12

CV 510

Figure 3.

10. Fuse: Use the 6,3A slow-blow fuse (see "Spare

Parts" section).

11. Hole Plug: For CO2gas heater socket (see

"Accessories" chapter - K14009-1 CO2Socket Kit).

12. Cooler Power Supply Socket: For supplying the

cooler unit only.

WARNING

The socket has an output of 230V, 2.5A and is protected

by the circuit breaker [13].

English 4 English

13. Circuit Breaker: Protects the Cooler

Power Supply socket [12]. It shuts off the

power supply when the current exceeds

2.5A. Press it to restore the power supply.

14. Power Lead (5m): Connect the supply plug to the

existing input cable that is rated for the machine as

indicated in this manual, and conforms to all

applicable standards. This connection shall be

performed only by a qualified person.

Welding Cables Connections

Insert the plug of the work cable into the socket [4] or [5].

The other end of this cable connects to the work piece

with the work clamp.

Connect the wire feeder to the power source:

insert the positive welding cable into the output

socket [8].

insert the wire feeder control cable into the socket [6]

(see "Accessories" section, Source/wire feeder cable

K10347-PG-xM or K10347-PGW-xM).

Use the shortest possible cable lengths

Machine and Circuit Protection

The CV425 / CV510 is protected against overheating,

overload and accidental short-circuits

If the machine is overheated, the thermal protection

circuit will decrease the output current to 0. The thermal

protection indicator [3] will turn on. The thermal

protection circuit will turn on the output current again,

when the machine is cooled.

The CV425 / CV510 is also electronically protected

against overload and accidental short-circuit. The

overload and short-circuit protection circuit automatically

reduces the output current to a safe value when it

detects an overload.

Maintenance

WARNING

For any repair operations, modifications or

maintenances, it is recommended to contact the nearest

Technical Service Center or Lincoln Electric. Repairs

and modifications performed by unauthorized service or

personnel will cause, that the manufacturer’s warranty

will become null and void.

Any noticeable damage should be reported immediately

and repaired.

Routine maintenance (everyday)

Check condition of insulation and connections of the

work leads and insulation of power lead. If any

insulation damage exists replace the lead

immediately.

Remove the spatters from the welding gun nozzle.

Spatters could interfere with the shielding gas flow to

the arc.

Check the welding gun condition: replace it, if

necessary.

Check condition and operation of the cooling fan.

Keep clean its airflow slots.

Periodic maintenance (every 200 working hours but

at list once every year)

Perform the routine maintenance and, in addition:

Keep the machine clean. Using a dry (and low

pressure) airflow, remove the dust from the external

case and from the cabinet inside.

If it is required, clean and tighten all weld terminals.

The frequency of the maintenance operations may vary

in accordance with the working environment where the

machine is placed.

WARNING

Do not touch electrically live parts.

WARNING

Before the case of welding machine will be removed, the

welding machine had to be turned off and the power lead

had to be disconnected from mains socket.

WARNING

Mains supply network must be disconnected from the

machine before each maintenance and service. After

each repair, perform proper tests to ensure safety.

Transport

Figure 4.

To ensure safety transport it is to:

Lift only power source without gas cylinder , cooler

and wire feeder,

Screw down an eye bolt and apply load axially in 45

degree angle in accordance to the drawing.

Ensure equal length of lifting lines.

English 5 English

Electromagnetic Compatibility (EMC)

11/04

This machine has been designed in accordance with all relevant directives and standards. However, it may still generate

electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or

other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand this

section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine..

This machine has been designed to operate in an industrial area. To operate in a domestic area it is

necessary to observe particular precautions to eliminate possible electromagnetic disturbances. The

operator must install and operate this equipment as described in this manual. If any electromagnetic

disturbances are detected the operator must put in place corrective actions to eliminate these disturbances

with, if necessary, assistance from Lincoln Electric.

Before installing the machine, the operator must check the work area for any devices that may malfunction because of

electromagnetic disturbances. Consider the following.

Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the

machine.

Radio and/or television transmitters and receivers. Computers or computer controlled equipment.

Safety and control equipment for industrial processes. Equipment for calibration and measurement.

Personal medical devices like pacemakers and hearing aids.

Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure

that all equipment in the area is compatible. This may require additional protection measures.

The dimensions of the work area to consider will depend on the construction of the area and other activities that are

taking place.

Consider the following guidelines to reduce electromagnetic emissions from the machine.

Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take

additional precautions such as filtering the input supply.

The output cables should be kept as short as possible and should be positioned together. If possible connect the

work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting the

work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.

Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special

applications.

WARNING

The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public

low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those

locations, due to conducted as well as radiated disturbances.

WARNING

This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to:

CV 425: Ssc ≥9,5 MVA

CV 510: Ssc ≥14,3 MVA

at the interface point between the user’s supply and the public system. It is the responsibility of the installer or user of the

equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected

only to a supply with a short circuit power Ssc greater than or equal to data on the table above.

English 6 English

Technical Specifications

NAME INDEX

CV 425 K14080-2A

CV 510 K14081-2A

INPUT

Input Voltage U1EMC Group / Class Frequency

CV 425 220/380/400V±10%

3 - phases II / A 50 / 60 Hz

CV 510

Input Power at Rated Cycle Input Amperes I1max cos φ

CV 425 23 kVA @ 60% Duty Cycle 60 A 0,89

CV 510 29,2 kVA @ 60% Duty Cycle 75 A 0,89

RATED OUTPUT

Duty Cycle 40°C

(based on a 10 min. period) Output Current Output Voltage

CV 425 60% 420 A 35 Vdc

100% 325 A 30,3 Vdc

CV 510 60% 500 A 39 Vdc

100% 385 A 33,3 Vdc

OUTPUT RANGE

Welding Current Range Open Circuit Voltage

CV 425 10 A ÷ 420 A 10 ÷ 39 Vdc

CV 510 10 A ÷ 500 A 10 ÷ 39 Vdc

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or Circuit Breaker Size Power Lead

220V 380V 440V

CV 425 D63 A D32 A D32 A 4 Conductor, 6 mm2

CV 510 D63 A D32 A D32 A 4 Conductor, 10 mm2

DIMENSION

Weight Height Width Length

CV 425 152 kg 880 mm 696 mm 1020 mm

CV 510 160 kg 880 mm 696 mm 1020 mm

Protection Rating Operating Humidity

(t=20°C) Operating Temperature Storage Temperature

IP23 ≤90 % from -10 ºC to +40 ºC from -25 ºC to +55 ºC

English 7 English

WEEE

07/06

Spare Parts

12/05

Part list reading instructions

Do not use this part list for a machine if its code number is not listed. Contact the Lincoln Electric Service

Department for any code number not listed.

Use the illustration of assembly page and the table below to determine where the part is located for your particular

code machine.

Use only the parts marked "●" in the column under the heading number called for in the assembly page (# indicate

a change in this printing).

First, read the Part List reading instructions above then refer to the "Spare Part" manual supplied with the machine,

which contains a picture-descriptive part number cross-reference).

Electrical Schematic

Refer to the "Spare Parts" manual supplied with the machine.

Accessories

K10347-PG-xxM Source/wire feeder cable (gas). Available in 5, 10, 15m.

K10347-PGW-xxM Source/wire feeder cable (gas and water). Available in 5, 10 or 15m.

K14009-1 CO2Socket Kit.

K14082-1 AV Meter Kit.

K14071-2 Grill Kit.

K14037-1 Cooler COOLARC 25.

English

Do not dispose of electrical equipment together with normal waste!

In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment

(WEEE) and its implementation in accordance with national law, electrical equipment that has reached

the end of its life must be collected separately and returned to an environmentally compatible recycling

facility. As the owner of the equipment, you should get information on approved collection systems

from our local representative.

By applying this European Directive you will protect the environment and human health!

This manual suits for next models

Table of contents

Other Lincoln Electric Welding System manuals

Lincoln Electric

Lincoln Electric LINC FEED 37 User manual

Lincoln Electric

Lincoln Electric INVERTEC POWER WAVE 450 SVM112-B User manual

Lincoln Electric

Lincoln Electric Compact 220 User manual

Lincoln Electric

Lincoln Electric MIG PULSER IM555 User manual

Lincoln Electric

Lincoln Electric RANGER IM836-B User manual

Lincoln Electric

Lincoln Electric RANGER 3 PHASE 11079 User manual

Lincoln Electric

Lincoln Electric INVERTEC SVM158-A User manual

Lincoln Electric

Lincoln Electric Coolarc 20 User manual

Lincoln Electric

Lincoln Electric PLASMA 20 IM10006 User manual

Lincoln Electric

Lincoln Electric 11626 User manual

Lincoln Electric

Lincoln Electric SYNERGIC 7F User manual

Lincoln Electric

Lincoln Electric POWER MIG210S User manual

Lincoln Electric

Lincoln Electric POWERTEC i320C STANDARD User manual

Lincoln Electric

Lincoln Electric SQUARE WAVE TIG 255 SVM100-A User manual

Lincoln Electric

Lincoln Electric RED-D-ARC LN-25 PRO EXTREME User manual

Lincoln Electric

Lincoln Electric MAGNUM 350 User manual

Lincoln Electric

Lincoln Electric ASPECT 375 User manual

Lincoln Electric

Lincoln Electric COBRAMAX IM774 User manual

Lincoln Electric

Lincoln Electric Power MIG 350MP User manual

Lincoln Electric

Lincoln Electric K3924-1 User manual

Lincoln Electric

Lincoln Electric POWER FEED IM916 User manual

Lincoln Electric

Lincoln Electric POWER MIG 140 User manual

Lincoln Electric

Lincoln Electric SVM 106-A User manual

Lincoln Electric

Lincoln Electric WELDMARK 225 User manual

Popular Welding System manuals by other brands

Berner

Berner PLASMACUT 54 instruction manual

Pro Spot

Pro Spot PR-155 Assembly instructions

Forney

Forney 210 operating manual

Thermal Arc

Thermal Arc 400S operating manual

GYS

GYS PROTIG 201 AC/DC Original instructions

TAFA

TAFA 30*8B35 owner's manual

ESAB

ESAB Buddy Arc 145 instruction manual

CIGWELD

CIGWELD 636804 use instructions

Red-D-Arc

Red-D-Arc DC-400 Operator's manual

Hobart Welding Products

Hobart Welding Products Spool Gun DP 3035-10 owner's manual

Elettro

Elettro HI-MIG 3000 SYNERGIC instruction manual

WIA

WIA Weldmatic 270 CP132-2 Operator's manual

Sonics

Sonics H520T instruction manual

Miller

Miller Big Blue 400D owner's manual

NewArc

NewArc RT2000 Operational manual

Hypertherm

Hypertherm powermax1000 Operator's manual

Everlast

Everlast POWER MTS 221STi Operator's manual

Kipor

Kipor KDE180XW Operator's manual