Lincoln Electric IM481-B manual Installation, Safety Precautions, FALLING EQUIPMENT can cause

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INSTALLATION

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.

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FUMES AND GASES can be danger- ous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

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WELDING SPARKS can cause fire or explosion.

Keep flammable material away.

Do not weld on closed containers.

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ARC RAYS can burn eyes and skin.

Wear eye, ear and body protection.

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See additional warning information at front of this operator’s manual.

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LOCATION

The machine should be located in a clean, dry place where there is free circulation of clean air such that air movement in through the front and out through the back will not be restricted. Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shut- down of the machine.

APPLICATION LIMITATIONS

There are no provisions on the CV 500-I for parallel- ing, and outdoor operations without rain sheltering is not recommended.

STACKING

WARNING

FALLING EQUIPMENT can cause

injury.

Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.

Lift only with equipment of adequate lifting capacity.

Be sure machine is stable when lifting.

Do not stack more than three high.

Do not stack the CV 500-I on top of any other machine.

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The units may be stacked three high by observing the following safety precautions.

1.Make sure the first or bottom unit is setting on a level, well supported surface.

2.The units must be stacked with their fronts flush, making sure the two holes in the base rails of the unit being stacked on top are over the two holes located on the top front corners of the unit it is being stacked on. Fasten the units together with 5/16 bolts, nuts and lockwashers through these holes.

3.Remove fastening bolts before lifting unit off stacks.

Input Power Connections

By removing the rear access panel the three phase input power is connected to the three line terminals on the input contactor, and the earth grounding lead to the grounding terminal on the input box floor marked with the symbol. Install the reconnect panel jumper links for the proper input voltage per the diagram pasted inside the access panel cover.

See Installation Data below:

INSTALLATION DATA

 

Input Rating

 

Recommended input wire and fuse sizes for maximum rated output.

 

 

 

 

 

In addition, follow latest National Electrical Code and Local Code.

 

 

 

 

 

Input Wire Size*

Minimum Grounding

BUSSMANN SUPER-LAG

 

 

 

 

Amperes**

(Type 75°C Copper

Wire Size

FUSE SIzE AND

 

 

 

 

on

Conductors in

(Copper Conductors)

CATALOG NUMBER***

 

Voltage

Hertz

Nameplate

Conduit) AWG

AWG

FUSE SIzE

CATALOG

 

 

 

 

 

 

 

 

NUMBER

 

220

 

78

3 (27mm2)

8 (10mm2)

100

REN-100

 

230

 

75

4 (21mm2)

8 (10mm2)

100

REN-100

 

380

50/60

45

6 (13mm2)

10 (5.3mm2)

60

RES-60

 

400

 

43

8 (8.4mm2)

10 (5.3mm2)

60

RES-60

 

440

 

39

8 (8.4mm2)

10 (5.3mm2)

50

RES-50

 

 

 

 

 

 

 

 

 

 

*Ambient temperature of 40°C (104°F).

**At rated output of 400A, 100% duty cycle.

***Use only Bussmann Super-Lag fuses specified. Other fuses may not protect the welder and may cause over- heating and possible fire damage.

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Contents Safety Depends on You IM481-BSafety Electric Shock can kill Welding and Cutting Sparks can Cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcPlease Examine Carton and Equipment For Damage Immediately Table of Contents Meanings of Graphic Symbols Power ON-OFF SwitchOutput Control LOCAL-REMOTE Switch Output Control DialCircuit Breaker Voltmeter SwitchThermal Protection Light Rating Plate Degree of protection provided by the enclosureEarth Ground Connection Signifying the Earth Ground ConnectionChassis Ground Connection Signifying the Chassis Ground ConnectionOperational Features & Controls General Machine DescriptionRecommended Processes & Equipment Design SummaryAuxiliary Power Connections Remote Control ConnectionsWATER COOLER CONNECTOR Case FeaturesParalleling Machine & Circuit Protection Thermal Protection LightMETER OPTION Technical Specifications Installation Safety PrecautionsInput Power Connections FALLING EQUIPMENT can causeInstallation of Field Installed Options Output Cable ConnectionsOutput Cables Electric Shock can killUndercarriages K817P, K841 Wire Feeder Control Cable ConnectionsConnection of CV 500-I to LN-22 or LN-25 Power Source Operation Safety Precautions ELECTRIC SHOCK can killOperating Instructions Duty Cycle Amps VoltsPIN LEAD NO Function Front View of 14-PIN Connector ReceptacleTerminal Strip Connections Routine Maintenance VAC Auxiliary Power for Water CoolerMachine and Circuit Protection Troubleshooting HOW to USE Troubleshooting GuideTROUBLESHOOTING GUIDE Trouble Cause What To DoFaulty Output Control potentiometer Trouble Cause What To Do Connecting the Remote Control to the Machine Fault Protection OperationPower I/O Switch Check Output VoltageRemote Control Check Power Rectifier Bridge Assembly Checking ProcedurePower Diode Test Power Silicon Controlled Rectifier TestRubber Boot Gate leads plug to Control P.C. board To plug To T1 main transformerEnhanced Diagram Page Page Precaucion Warnung