Lincoln Electric CV 510 User manual

IM3032

09/2022

REV06

CV 425 & 510

OPERATOR’S MANUAL

ENGLISH

Lincoln Electric Bester Sp. z o.o.

ul. Jana III Sobieskiego 19A, 58-260 Bielawa, Poland

www.lincolnelectric.eu

English I English

12/05

THANK YOU! For choosing the QUALITY of the Lincoln Electric products.

Please check packaging and equipment for damage. Claims for material damaged in shipment must be notified

immediately to the dealer.

For ease of use, please enter your product identification data in the table below. Model Name, Code & Serial

Number can be found on the machine rating plate.

Model Name:

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

Code & Serial number:

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

Date & Where Purchased:

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

ENGLISH INDEX

Technical Specifications...................................................................................................................................................... 1

ECO design information ...................................................................................................................................................... 2

Electromagnetic Compatibility (EMC).................................................................................................................................. 4

Safety.................................................................................................................................................................................. 5

Installation and Operator Instructions.................................................................................................................................. 7

WEEE ............................................................................................................................................................................... 11

Spare Parts ....................................................................................................................................................................... 11

REACh .............................................................................................................................................................................. 11

Authorized Service Shops Location .................................................................................................................................. 11

Electrical Schematic.......................................................................................................................................................... 11

Accessories....................................................................................................................................................................... 12

English 1 English

Technical Specifications

NAME INDEX

CV 425 K14080-1A

CV 510 K14081-1A

INPUT

Input Voltage U1EMC Group / Class Frequency

CV 425 230 / 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 57 A 0,89

CV 510 29,2 kVA @ 60% Duty Cycle 73 A 0,89

RATED OUTPUT

Duty Cycle 40°C

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

CV 425 60% 420A 35Vdc

100% 325A 30,3Vdc

CV 510 60% 500A 39Vdc

100% 385A 33,3Vdc

OUTPUT RANGE

Welding Current Range Open Circuit Voltage

CV 425 10A ÷ 420A 10 ÷ 39 Vdc

CV 510 10A ÷ 500A 10 ÷ 39 Vdc

RECOMMENDED INPUT CABLE AND FUSE SIZES

Fuse or Circuit Breaker Size Power Lead

230V 400V

CV 425 D63A D32A 4 Conductor, 6 mm2

CV 510 D63A D32A 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 2 English

ECO design information

The equipment has been designed in order to be compliant with the Directive 2009/125/EC and the Regulation

2019/1784/EU.

Efficiency and idle power consumption:

Index Name Efficiency when max power consumption

/ Idle power consumption Equivalent model

K14080-1A CV 425 74,2% / 300W No equivalent model

K14081-1A CV 510 73,2% / 400W No equivalent model

Idle state occurs under the condition specified in below table

IDLE STATE

Condition Presence

MIG mode

TIG mode

STICK mode

After 30 minutes of non-working

Fan off X

The value of efficiency and consumption in idle state have been measured by method and conditions defined in the product

standard EN 60974-1:20XX

Manufacturer’s name, product name, code number, product number, serial number and date of production can be read from

rating plate.

XXXXXXXXXX

Code: XXXXX XXXXXX-X

S/N: P1YYMMXXXXX

P1 YY MM XXXXX

5A5A 5B 5D5C

XXXXXXX

Where:

1- Manufacturer name and address

2- Product name

3- Code number

4- Product number

5- Serial number

5A- country of production

5B- year of production

5C- month of production

5D- progressive number different for each machine

English 3 English

Typical gas usage for MIG/MAG equipment:

Material type

Wire

diameter

[mm]

DC electrode positive Wire Feeding

[m/min] Shielding Gas Gas flow

[l/min]

Current

[A]

Voltage

[V]

Carbon, low

alloy steel 0,9 ÷ 1,1 95 ÷ 200 18 ÷ 22 3,5 – 6,5 Ar 75%, CO225% 12

Aluminium 0,8 ÷ 1,6 90 ÷ 240 18 ÷ 26 5,5 – 9,5 Argon 14 ÷ 19

Austenic

stainless steel 0,8 ÷ 1,6 85 ÷ 300 21 ÷ 28 3 - 7 Ar 98%, O22% /

He 90%, Ar 7,5% CO22,5% 14 ÷ 16

Copper alloy 0,9 ÷ 1,6 175 ÷ 385 23 ÷ 26 6 - 11 Argon 12 ÷ 16

Magnesium 1,6 ÷ 2,4 70 ÷ 335 16 ÷ 26 4 - 15 Argon 24 ÷ 28

Tig Process:

In TIG welding process, gas usage depends on cross-sectional area of the nozzle. For commonly used torches:

Helium: 14-24 l/min

Argon: 7-16 l/min

Notice: Excessive flow rates causes turbulence in the gas stream which may aspirate atmospheric contamination into the

welding pool.

Notice: A cross wind or draft moving can disrupt the shielding gas coverage, in the interest of saving of protective gas use

screen to block air flow.

End of life

At end of life of product, it has to be disposal for recycling in accordance with Directive 2012/19/EU (WEEE), information

about the dismantling of product and Critical Raw Material (CRM) present in the product, can be found at

https://www.lincolnelectric.com/en-gb/support/Pages/operator-manuals-eu.aspx

English 4 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 5 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.

English 6 English

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.

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.

English 7 English

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 3x230V

50/60Hz and 3x400V 50/60Hz (3x400V: 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:

3x230V

3x400V

Figure 1.

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.

English 8 English

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).

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].

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.

11 12

CV 425

11 12

CV 510

Figure 3.

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