Lincoln Electric Invertec CV500 User manual

Rev. 03
IM7005-1
July, 2012
Rev. 03
INVERTEC® CV/CC500
For use with machine Part Number K60051-1, Code 76072
•World’s Leader in Welding and Cutting•
THE SHANGHAI LINCOLN ELECTRIC COMPANY
No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907
www.lincolnelectric.com.cn
Copyright © 2009 The Shanghai Lincoln Electric Company
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 thoughtful
operation on you 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.

Rev. 03
Thank you for selecting QUALITY Lincoln Electric products.
Please examine the packaging and equipment for damage. Claims for material damaged in shipment must be
notified immediately to the authorized dealer from whom you purchased the machine.
For future reference,please record your equipment identification information in the table below. Model Name,
Code & Serial Number can be found on the machine rating plate.
Model Name
□Invertec®CV/CC500
Code & Serial number
Date & Where Purchased
Authorized dealer’s shop
Declaration of conformity
THE SHANGHAI LINCOLN ELECTRIC COMPANY
Designed in conformance with the following norm:
GB15579.1
EN 60974-1
THE SHANGHAI LINCOLN ELECTRIC COMPANY
No. 195, Lane 5008, Hu Tai Rd. Baoshan, Shanghai, PRC 201907

iSAFETY i
INVERTEC®CV/CC500
Rev. 03
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.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR
PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous.
1.a Electric current flowing through any conductor
causes localized Electric and Magnetic Field
(EMF). Welding current creates EMF fields
around welding cables and welding machines.
1.b EMF fields may interfere with some pacemakers,
and welders having a pacemaker should consult
their physican before welding.
1.c All welders should use the following procedures
in order to minimize exposure to EMF fields from
the welding circuit:
1.c.1 Route the electrode and work cables
together –Secure them with tape when
possible.
1.c.2 Never coil the electrode lead around your
body.
1.c.3 Do not place your body between the
electrode and work cables. If the electrode
cable is on your right side, the work cable
should also be on your right side.
1.c.4 Connect the work cable to the workpiece as
close as possible to the area being welded.
ARC RAYS can burn.
2.a Use a shield with the proper filter and cover
plates to protect your eyes from sparks and the
rays of the arc. Headshield and filter lens should
conform to ANSI Z87. I standards.
2.b Use suitable clothing made from durable flame-
resistant material to protect your skin and that of
your helpers from the arc rays.
2.c Protect other nearby personnel with suitable,
non-flammable screening and/or warn them not
to watch the arc nor expose themselves to the
arc rays or to hot spatter or metal.
ELECTRIC SHOCK can
kill.
3.a The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do not
touch these “hot” parts with your bare skin or wet
clothing. Wear dry, hole-free gloves to insulate
hand.
3.b Insulate yourself from work and ground using dry
insulation. Make certain the insulation is large
enough to cover your full area of physical contact
with work and ground.
In addition to the normal safety precautions,
if welding must be performed under
electrically hazardous conditions (in damp
locations or while wearing wet clothing; on
metal structures such as floors, grating or
scaffolds; when in cramped positions such
as sitting, kneeling or lying, if there is a high
risk of unavoidable or accidental contact with
the workpiece or ground) use the following
equipment:
Semiautomatic DC Constant Voltage (Wire)
Welder.
DC Manual (Stick) Welder.
AC Welder with Reduced Voltage Control.
3.c In semiautomatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or
semiautomatic welding gun are also electrically
“hot”.
3.d Always be sure the work cable makes a good
electrical connection with the metal being
welded. The connection should be as close as
possible to the area being welded.
3.e Ground the work or metal to be welded to a good
electrical (earth) ground.
3.f Maintain the electrode holder, work clamp,
welding cable and welding machine in good, safe
operating condition. Replace damaged
insulation.
3.g Never dip the electrode in water for cooling.
3.h Never simultaneously touch electrically “hot”
parts of electrode holder to two welders because
voltage between the two can be total of the open
circuit voltage of both welders.

ii SAFETY ii
INVERTEC®CV/CC500
Rev. 03
FUMES AND GASES
can be dangerous.
4.a Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your
head out of fume. Use enough ventilation and/or
exhaust at the arc to keep fumes and gases
away from the breathing zone. When welding
with electrodes which require special
ventilation such as stainless or hard facing
(see instructions on container or MSDS) or on
lead or cadmium plated steel and other
metals or coatings which produce highly
toxic fumes, keep exposure as low as
possible and below Threshold Limit Values
(TLV) using local exhaust or mechanical
ventilation. In confined spaces or in some
circumstances, outdoors, a respirator may be
required. Additional precautions are also
required when welding on galvanized steel.
4.b Do not weld in locations near chlorinated
hydrocarbon vapors coming from degreasing,
cleaning or spraying operations. The heat and
rays or the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other
irritating products.
4.c Shielding gases used for arc welding can
displace air and cause injury or death. Always
use enough ventilation, especially in confined
areas, to insure breathing air is safe.
4.d Read and understand the manufacturer’s
instructions for this equipment and the
consumables to be used, including the material
safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are
available from your welding distributor or from
the manufacturer.
FOR ELECTRICALLY
powered equipment.
5.a Turn off input power using the disconnect switch
at the fuse box before working on the equipment.
5.b Install equipment in accordance with the national
standard, all local standards and the
manufacturer’s recommendations.
5.c Ground the equipment in accordance with the
national standards and the manufacturer’s
recommendations.
WELDING SPARKS
can cause fire or
explosion.
6.a Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember
that welding sparks and hot materials from
welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily
available.
6.b When not welding, make certain no part of the
electrode circuit is touching the work or ground.
Accidental contact can cause overheating and
create a fire hazard.
6.c Do not heat, cut or weld tanks, drums or
containers until the proper steps have been
taken to insure that such procedures will not
cause flammable or toxic vapors from subtances
inside. They can cause an explosion even
though they have been “cleaned”.
6.d Sparks and spatter are thrown from the welding
arc. Wear oil free protective garments such as
leather gloves, heavy shirt, cuffless trouses, high
shoes and a cap over your hair.
CYLINDER may
explode if damaged.
7.a 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. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b Always keep cylinders in an upright position
securely chained to an undercarriage or fixed
support.
7.c Cylinder should be located:
Away from areas where they may be struck or
subjected to physical damage.
A safe distance from arc welding or cutting
operations and any other source of heat,
sparks, or flame.
7.d Never allow the electrode, electrode holder or
any other electrically “hot” parts to touch a
cylinder.
7.e Keep your head and face away from the cylinder
valve outlet when opening the cylinder valve.
7.f Valve protection caps should always be in place
and hand tight except when the cylinder is in use
or connected for use.

A -1INSTALLATION A-1
INVERTEC®CV/CC500
Rev. 03
TECHNICAL SPECIFICATIONS –INVERTEC®CV/CC500
INPUT –THREE PHASE ONLY
Standard Voltage / Phase / Frequency
380V ~ 415V (±10%) / 3 / 50 or 60 Hz
RATED OUTPUT –DC ONLY
Max Input Power at Rated Output ( SMAW )
23 kVA @ 60% Duty Cycle
Welding Mode
Duty Cycle
Amperes
Volts at Rated Amperes
GMAW
60%
100%
500A
390A
39V
33.5V
SMAW ( STICK )
60%
100%
500A
390A
40V
35.6V
GTAW ( TIG )
60%
100%
500A
390A
30V
25.6V
OUTPUT RANGE
Welding Mode
Welding Current Range
Open Circuit Voltage
Welding Voltage Range
GMAW
50A ~ 500A
67V
16 V ~ 39V
SMAW ( STICK )
30A ~ 500A
67V
21.2 V ~ 40V
GTAW ( TIG )
5A ~ 500A
67V
10.2 V ~ 30V
RECOMMENDED INPUT WIRE AND FUSE SIZES
INVERTEC®CV/CC500
Input Voltage/
Frequency (Hz)
342~456 V/
50Hz or 60Hz
Maximum
Input
Ampere
51A
Maximum
Effective
Supply
Current
40A
60°C Copper
Wire in
Conduct
Sizes
12mm2
Fuse or
Breaker Size
(Super Lag)
60A
Grounding
Conductor
Size
10mm2
PHYSICAL DIMENSIONS
INVERTEC®CV/CC500
Height
Width
Depth
Weight
480mm
350mm
840mm
56Kg
Temperature Range
Operating Temperature Range
-10°C ~ +40°C
Storage Temperature Range
-25°C ~ +55°C
For any maintenance or repair operation it is recommended to contact the nearest technical service center or directly
consult machine division of the Shanghai Lincoln Electric. Maintenance or repairs performed by unauthorized service
center or personnel will void the manufacturer’s warranty.

A -2INSTALLATION A-2
INVERTEC®CV/CC500
Rev. 03
SAFETY PRECAUTIONS
Read the entire installation section before starting
installation.
ELECTRIC SHOCK can kill.
Only qualified personnel
should perform this
installation.
Turn the input power OFF at
the main switch or fuse box
before working on this equipment. Turn off the
input power to any other equipment connected to
the welding system at the main switch or fuse
box before working on the equipment.
Do not touch electrically “Hot”parts.
Always connect the INVERTEC®grounding lug
(located at the rear of the case) to a proper safety
(Earth) ground. INVERTEC®is for use on a 4 wire
system with earthed neutral.
SELECT SUITABLE LOCATION
This power source should not be subjected to falling
water, nor should any parts of it be submerged in water.
Doing so may cause improper operation as well as
pose a safety hazard. The best practice is to keep the
machine in a dry, sheltered area.
The bottom of machine must always be placed on a
firm, secure, level surface. There is a danger of the
machine toppling over if this precaution is not
taken.
Place the welder where clean cooling air can freely
circulate in through the back louvers and out through
the case sides. Water,dirt, dust or any foreign material
that can be drawn into the welder should be kept to a
minimum. Failure to observe these precautions can
result in excessive operating temperatures and
nuisance shutdowns.
Locate the INVERTEC®machine away from radio
controlled machinery. Normal operation of the welder
may adversely affect the operation of RF controlled
equipment, which may result in bodily injury or damage
to the equipment.
STACKING
The INVERTEC®machine may be stacked 3 high. Be
sure to locate the machines on a firm level surface and
align the pins in the roofs of the lower unit with the
holes in the base of the upper unit.
Two INVERTEC®CV /CC machines can be stacked
together through the two holes ( 1.1 ) and the two pins
( 1.2 ). Please see FIGURE A.1.
The INVERTEC®CV/CC machine can be moved using
the handles ( 1.3 ). Please see FIGURE A.1.
FIGURE A.1
INPUT POWER AND GROUNDING
CONNECTION
Only a qualified electrician should connect the
input leads to the INVERTEC®. Connections should
be made in accordance with the connection
diagram. Failure to do so may result in bodily injury
or death.
Open the input box on the rear of the case. Use a
three-phase supply line, the three live wires should go
through the three holes of the input wire holder and be
securely clamped and fixed. Connect L1, L2, L3 and
ground according to the Input Supply Connection
Diagram decal, refer to Figure A.2 on this page.
Make sure the amount of power available from the input
connection is adequate for normal operation of the
machine. Refer to the Technical Specifications at the
beginning of this Installation section for recommended
fuse and wire sizes. Fuse the input circuit with the
recommended super lag fuse or delay type breakers.
Using fuses or circuit breakers smaller than
recommended may result in “nuisance” shut-offs from
welder inrush currents, even if the machine is not being
used at high currents.
WARNING
CAUTION
WARNING
FIGURE A.2

A -3INSTALLATION A-3
INVERTEC®CV/CC500
Rev. 03
PROCESS SELECTIONS AND
CONNECTIONS
ELECTRIC SHOCK can kill.
Only qualified personnel
should perform this
installation.
Turn the input power OFF at
the main switch or fuse box before working on
this equipment. Turn off the input power to any
other equipment connected to the welding
system at the main switch or fuse box before
working on the equipment.
Do not touch electrically “Hot”parts.
Always connect the INVERTEC®grounding lug
(located at the rear of the case) to a proper safety
(Earth) ground. INVERTEC®is for use on a 4 wire
system with earthed neutral.
WORK CONNECTION
Connect a work lead of sufficient size between the
proper output stud on the power source and the work.
Be sure the connection to the work makes tight metal to
metal electrical contact. Poor work lead connections
can result in poor welding performance.
To avoid interference problems with other equipment
and to achieve the best possible operation, route all
cables directly to the work and wire feeder. Avoid
excessive lengths and do not coil excess cable.
Cable sizes are increased for greater lengths primarily
for the purpose of minimizing cable drop.
Minimum work and electrode cable sizes are as follows:
TABLE A.1
Current (60% Duty Cycle)
Minimum Copper
Work Cable Size
200A
300A
400A
500A
Up To 30m Length
30 mm2
50 mm2
70 mm2
95 mm2
Note: The recommended cable size may need to
change depending on its quality. When the rated
current flow goes through, the total voltage drop on
ground cable and electrode cable must not exceed 4
volts.
GMAW PROCESS ( CV MODE ) WIRE FEEDER CONNECTION
1. PWF WIRE FEEDER ( FIGURE A.3 )
WELDING CABLE
NEGATIVE
STUD
-+
POSITIVE
STUD
WIRE
FEEDER
CONNECTOR
REMOTE
CONTROL
CONNECTOR
INVERTEC CV/CC WELDER
R
WELDING TORCH
GAS HOSE
GAS REGUL ATOR
ELECTRODE
PWF WIRE FEEDER
WORK WORK CLAMP
CONTROL CABLE
SHIELDING GAS
CYLINDER
FIGURE A.3
WARNING

A -4INSTALLATION A-4
INVERTEC®CV/CC500
Rev. 03
2. LN-25 PRO FEEDER ( FIGURE A.4 )
WELDING TORCH WELDING CABLE
GAS HOSE
GAS REGULATOR
LN-25PRO
SHIELDING GAS
CYLINDER
WORK WORK CLAMP
VSENSE LEAD
NEGATIVE
STUD
-+
POSITIVE
STUD
WIRE
FEEDER
CONNECTOR
REMOTE
CONTROL
CONNECTOR
INVERTEC CV/CC WELDER
R
REMOTE
CONTROL BOX
FIGURE A.4
3. GTAW PROCESS ( CC MODE ) CONNECTION ( FIGURE A.5 )
WORK CLAMP
WELDING
TORCH
GAS
HOSE
GAS
REGULATOR SHIELDING
GAS
CYLINDER
WORK
REMOTE
CONTROL BOX
NEGATIVE
STUD
-+
POSITIVE
STUD
WIRE
FEEDER
CONNECTOR
REMOTE
CONTROL
CONNECTOR
INVERTEC CV/CC WELDER
R
FIGURE A.5

A -5INSTALLATION A-5
INVERTEC®CV/CC500
Rev. 03
4. SMAW PROCESS ( CC MODE ) CONNECTION ( FIGURE A.6 )
WELDING TORCH
WORK CLAMP
WORK
NEGATIVE
STUD
-+
POSITIVE
STUD
WIRE
FEEDER
CONNECTOR
REMOTE
CONTROL
CONNECTOR
INVERTEC CV/CC WELDER
R
REMOTE
CONTROL BOX
FIGURE A.6
For secure electrical connection, the screws
connecting the output terminals and cables must
be tightened. Damage may occur to the output stud
or welding performance maybe compromised.
6-PIN PWF WIRE FEEDER CONNECTOR
INSTRUCTION
Please see FIGURE A.7 and TABLE A.2 for more
details.
6-PIN AMPHENOL CONNECTOR INSTRUCTION
Please see FIGURE A.8 and TABLE A.3 for more details.
CAUTION
A
B
C
D
EF
FIGURE A.7FIGURE A.8

A -6INSTALLATION A-6
INVERTEC®CV/CC500
Rev. 03
SAFETY PRECAUTIONS
Read this entire section of operating
instructions before operating the machine.
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 closed
containers.
ARC RAYS can burn eyes and
skin.
Wear eye, ear and body
protection.
PLEASE SEE ADDITIONAL WARNING
INFORMATION AT THE FRONT OF THIS
OPERATOR’S MANUAL.
DUTY CYCLE
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.
60% duty cycle:
Weld for 6 minutes
Break for 4 minutes
Excessive extension of the duty cycle will cause the
thermal protection circuit to activate.
THERMAL PROTECTION
The INVERTEC®machine is equipped with a thermal
protection device. When the machine has gone into
thermal overload, the output will be turned off and the
thermal indicator light will be turned “ON“. When the
machine has cooled to a safe temperature, the Thermal
Indicator Light will go out and the machine may resume
normal operation.
Note: For safety reasons the machine’s welding output
will not come on after a thermal shutdown until the
output is disabled and re-enabled.
WARNING
TABLE A.2
Power Source
Wire Feeder
Pin
Function
Lead #
Pin
Function
Lead #
1
“ + ” pulse signal for motor control.
91
1
Positive terminal of motor.
91
2
“ + ” pulse signal for gas solenoid.
92
2
Connected to one lead of gas
solenoid.
92
3
“ + ” control signal for gas purge, cold
inch and trigger.
93
3
Control signals output ( gas purge,
cold inch and trigger ).
93
4
+/- 10V control signal for arc current
and arc voltage.
94
4
Control signals output (arc current
and arc voltage ).
94
5
GND for arc current, arc voltage, gas
purge, cold inch and trigger control.
95
5
Common GND.
95
6
GND for gas solenoid and motor
control.
96
6
Negative terminal of motor; and
connected to another lead of gas
solenoid.
96
TABLE A.3
Power Source
Remote Controller
Pin
Function
Lead #
Pin
Function
Lead #
A
Output control power +
77
A
Pot foot 1
77
B
Output control signal
76
B
Pot foot 2
76
C
Output control power -
75
C
Pot foot 3
75
D
Output control switch +
2
D
Switch foot 1
2
E
Output control switch -
4
E
Switch foot 2
4
F
Ground lead ( case )
G2
F
Case
G2