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INSTALLATION

Safety Precautions

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
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 t he top front corner s 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:
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 danger-
ous.
• 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 closed containers.
------------------------------------------------------------------------
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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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 an y oth er
machine.
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WARNING
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.