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Lincoln Electric IDEALARC SVM136-A User's Manual

1. i I 20 Se RECTIFIER BRIDGE TU ne 9 M A VOLTAGE BUFFER V 7 7 A 15V l T M z NU 9 6 zl H 3 25 I A POWER UP 8 sm s gt 2 pi OUTPUT CLAMP E d De 1 gt e b rk pi naci rm M 4222 8 wx gt JP mo C D3 D EIE f T 080 PX ax s so kl jg yor Elan SES s T EP I else C39 3 e Y eo amp Ld 2 S W I T T DAS 35V 1 50K a 10K T bs EK E 562 2 562 20 V Mie An PE 7 Set T wa F hax zz ew r D74 WM 15V SUPPLY TE 33 2K e e 23 eo Jee a x5 e e ES oss p69 p70 C40 e 475K on N A Moov Ao aT Jes o z 1 SCR T 7 1 1 WEE 4 gt DT2 D73 SI CURRENT au roe a Dm Ela bow A 270 25W SWITCH 2 87K Ge Jo vos 02 2
2. NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine 345 VOLTS oA 51 C 115V m TO GROUND PER CIRCUIT 31 Hi Xi NATIONAL ELECTRICAL P BREAKER 32 CONNECT OR CODE 10AMP INSULATE AS THIS CONNECTION N B e H2 To SUPPLY DOES NOT APPEAR ON 50 TT CIRCUIT 42 SHOWN ON HA 115V H3 LINES 220 380 440V AND B5 BREAKER j INPUT H3o Xi tst eu P 230 400V NACHINES oN in x CONNECTION H4e Pisa 300 ra M IH oroe i 42A SECONDARY PRIMARY T2 CONTROL i Se cum 3 Fw k E i THERMOSTAT THERMOSTAT TRANSFORMER l bs 41 olo NE S 9 S 4 gt L n O lO AUXILIARY 202 SEE en Heg EUIS rir COILS d 21V Ga CAPACITOR cla i z S TRANSFORMER NG te DISCHARGE H d 4 olo i S g 204 i i L4 i Hd n BOTTOM 4 5o 6 i og PRIMARY sto 2 s Hol CAPACITOR o i 1 3 i DISCHARGE i o i 16 17 18 i BE 0 5 50W i i e NA 10 5 60W E i 5 Unc sole la tese olea scc pe ted Loci SIS ol 0 220 EAR JI pp ER T or i 31 000MFD 204 ene ere 50V EACH i CT 5 RECTIFIER i OPTION iz ASSEMBLY SCH i SHUNT
3. Section D Safety Precautioris 5 eebe Ce ee Mee EE D 2 Routine and Periodic Maintenance D 2 Major Component LOCatOnS sitesi uu revenir reete ka t an ct a aaa ee ae D 3 Theory of Operation 1i iiec gri lla a Bl s caste pana ea Section E Troubleshooting and Repair Section F How to Use Troubleshooting Guide iiie nitent car res enden rakka F 2 PC Board Troubleshooting Procedures enne F 3 Troubleshooting GUAE sisaria oa aha a gta etui n auqa e F 4 Ie lcm EE F 10 ele elle F 28 Iteplacement Procedures 3 iiec petere esie oa cette pese ie osx does ue E eux eeu aa F 32 RoS AllorBo palu m M F 53 Parts Mapual m8 P 236 IDEALARC CV 400 LINCOLN B DEC 97 Section A 1 Section A 1 TABLE OF CONTENTS INSTALLATION SECTION o O 5 Ist Le j u u u D uu y nue me Section A Technical Specifications ttt ciet teret tere a nue Rc pectet ute cues A 2 Q Salety Wee Te E A 3 Location and Ventilgliegil uu uu uuu u u u u S A 3 o LIMIN ua aasan ta sb A 3 lt Sire dom E A 3 dili a A 3 Electrical ores eren eee A 3 Ground Kao Tia re 01 ERR EE A 4 Input Power Supply Connections aaaaaasaaaasaaasanannnannnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnanani A 4 Input Wire and FUSE SIZE uy itn eee i rhe et uk dba
4. Plug P3 o O amp 9 o o o 2 il 5 O x Return to Master TOC Plug P1 Plug P1 PHASE ANGLE WINDING VOLTAGES olo O10 E From Lead A To Lead Expected VAC 2 2 ols 201 204 21 VAC 2 2 202 204 21 VAC EE 5 5 SIS 203 204 21 VAC cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 21 F 21 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if an SCR or diode is shorted or leaky See the Machine Waveform Section in this manual for normal and abnormal output waveforms Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt ohmmeter Multimeter 5 16 Nut
5. Remove the four mounting nuts and associ ated flat and lock washers that hold the motor to the mounting bracket See Figure F 18 6 Carefully remove the fan motor 7 To replace the fan motor mount the motor to 10 IDEALARC CV 400 LINCOLN B its mounting bracket using the four nut and associated flat and lock washers Resplice any motor leads cut for removal Soldering the wires is recommended Reattach the fan blade if it was removed earlier using the Allen head wrench to tighten it to the motor shaft Install the case top and sides F 36 F 36 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT AA WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in the removal and rep
6. oc 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 Read and understand the following safety highlights For additional safety information it is strongly recommended that you pur chase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS f A A A FOR ENGINE 8 7 us 1 h To avoid scalding do not remove the H x 5 s radiator pressure cap when the engine is powered equipment ANA Br P x 1 a Turn the engine off before troubleshooting and maintenance 3 work unless the maintenance work requires it to be running 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors Return to Master TOC ELECTRIC AND I Ss MAGNETIC FIELDS 1 c Do not add the fuel near an open flame weld S may be dangerous ing arc or when the engine is running Stop the engine and allow it to cool before refuel 2 a Electric current flowing through any conductor causes ing to prevent spilled fuel
7. i ul D pee ll LEAD NOT PRESENT 7 5 ann 205 206 WITH DIODE OPTION SNUBBER Lea ng BOARD G2 224 RE E S ss wi qassussssSs Oo O es 4 p 124 3 P2 I Oo ESI VOLTMETER i TTT T i gt 205 225 201 2 ze F T 2984 i J8 Od ELECTRICAL SYMBOLS PER E1537 o ees e 3 gt 212 1 le2to1 V NA Jet z 4 ETE Ji 4 gt 22044 51 o a t lo 4 i i J2 i 182 o I L 1 204 FG 5 gt 205 4 31 73 n C6 H le lT b 208 RH 6 563 208 42 84 0047MFD NL 3 i i o o 1400V 10 31 2 i T 372134 4 PIN 8 PIN ti i SH CH i J8 J1J2 amp J5 cjg TS2 19 329 i CONTROL BOARD 8 gt 75 4 CONNECTOR CAVITY 5 i NUMBERING SEQUENCE SIS COMPONENT SIDE OF P C Li Sth 075 0 bp BOARD D OUTPUT CONTROL BOARD CHOKE i 10A peers 32 CIRCUIT GROUNDING LEAD NOTES eg 4 BREAKER N A CIRCUITRY PRESENT ON EE O O o 82A I CAPACITOR DISCHARGE ONLY _ 240 N B TAPE UP SEPARATELY ME S ae 7 TO PROVIDE AT LEAST Lp I Pi pa Ji 25 als 600 V INSULATION J 8 W Ke N C CIRCUITRY PRESENT ON in R Y IRURE DIODE OPTION ONLY 76 Ld JJ 7 10K CN PILOT 231 ut OUTPUT FR N D THESE LEADS ARE PRESENT P E CONTROL PROTECTION LIGHT 81 WITH METER OPTION ONLY i LIGHT POWER 5 SR SIN N E 220V WINDING PLUG O i Q AND CIRCUIT BREAKER OJO ARE PRESENT ONLY It 2 ON CV500 1 Glo L 224 N F 81 AND 32 ARE NOT Se s
8. 77 lt gt NEGATIVE POSITIVE ELECTRODE L EN CABLE Ho AUTOMATI WORK EQUIPMENT IDEALARC CV 400 LINCOLN B C 8 NOTES IDEALARC CV 400 LINCOLN NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes oj uumeg Section D 1 Section D 1 TABLE OF CONTENTS o MAINTENANCE Maintenance SRM Section D Safety ec Im D 2 Routine and Periodic Mamtenance a D 2 E Major Component LOGCalions uu eterne rtr hr etae FEE e gja a adik H ERR a a Perg x nu eer D 3 ke Return to Master TOC o O E E 7 c x E o x Return to Master TOC IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC olo O o EE 58 n o G AIS o cic 3 2 ol aja Return to Section TOC Return to Master TOC Return to Master TOC D 2 D 2 MAINTENANCE SAFETY PRECAUTIONS AA WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance e Turn the input power OFF at the discon nect switch or fuse box before working on this equipment Do not touch electrically hot parts ROUTINE AND PERIODIC MAINTENANCE WARNING To avoid receiving an electric shock keep electrode holders and cable insulation
9. ELECTRICAL DIAGRAMS Wiring Diagram Codes 10084 10085 10086 CR1 CONTACTOR y 238 H1 SING LE VOLTAGE OVER H3 G 2 R1 CONTACTOR 233 COILS TO PRIMARY 233 FAN MOTOR CONTACTOR 233 CRI Hi 12 7 NA H R JUMPER H TO PRIMARY COILS FLEX LEAD e o EE K x CAE o Z DUAL A SINGLE VOLTAGE TO GROUND 230 400 VOLTAGE TO GROUND 380 500 V TO GROUND NB es 220 380 440 VOLTAGE o UNDER 346 VOLTS PER NATIONAL SHOWN CONNECTED PER NATIONAL SHOWN CONNECTED PER NATIONAL Lle SHOWN CONNECTED FOR 220 V o Sa a CODE FOR 230 V ELECTRICAL CODE FOR 380 V ELECTRICAL CODE ol o N B e H3 o supply N B H3 5 suppLY 7 RECONNECT PANEL H2 LINES B He unes RECONNECT id d NB is eu RECONNECT PANEL TO SUPPLY c faxo N eet H2 LINES EIS xi USD xi RUP Xia lu He TO GROUND P Wo Witte 5 NR PER NATIONAL SIS M Reide f in ELECTRICAL c c 232 5 M 232 bp d pe CRI
10. IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 Fle s s Ri Hie EK gje ol cc a Return to Section TOC Return to Master TOC Return to Master TOC INSTALLATION CONNECT WIRE FEEDERS The wire feeder control cable can connect to the CV 400 at the 14 pin amphenol on the front of the machine with the appropriate adapter cable or the terminal strips behind the hinged control panel cover A strain relief box connector is provided for cable access to the terminal strips The wire feeder grounding wire con nects to a chassis ground screw provided near the ter minal strips and marked with the ground symbol 777 See the Accessories section of this manual for specif ic instructions for connecting the following automatic and semiautomatic wire feeders to the CV 400 Automatic Wire Feeders NA 3 NA 5 NA 5R Semiautomatic Wire Feeders LN 7 LN 7 GMA LN 8 LN 9 LN 9 GMA LN 22 LN 23P LN 25 LN 742 IDEALARC CV 400 LINCOLN B Section B 1 Section B 1 TABLE OF CONTENTS o P OPERATION SECTION k OPCS ration sci u L hai u nuna chs i aE a a a a q uE adaa uqa kasqas as a Takka Section B Safety PrECAULONS va u uyu jk B 2 E General Descriptio u u B 3 5 Recommended Processes irran NE AA EEEE AEAEE n n HON ka on B 3 d Operational Features and Controls aaaaaaaaaaasaaaasaaasa
11. x E O x Return to Section TOC Return to Master TOC o O Hr E 7 x 3 o x F 6 F 6 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine has high welding out put and no control The machine has minimum or very low welding output and no control POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS If remote control is being used set the Output Control Switch S2 to the Machine or Local position and control the weld output with the machine Output Control R4 If the problem is solved check the remote con trol unit or wire feeder and asso ciated control cable Check the remote control leads for grounds to the negative welding output If leads 75 76 or 77 are grounded to the negative welding output the machine output may go very high without control If remote control is being used set the Output Control Switch S2 to the Machine or Local position and control the weld output with the machine Output Control R4 If the problem is solved check the remote con trol unit or wire feeder and asso ciated control cable Make certain the remote control leads 75 76 77 are not grounded to the positive welding output Make certain the three phase input voltage is correct and matches the machine rating and the reconnect panel TROUBLESHOOTING
12. Check the input power switch S1 for proper operation See the Wiring Diagram Check the leads associated with the power switch S1 and the control transformer T2 for loose or faulty connections See the Wiring Diagram 3 Perform the Transformer Test The machine is dead no output no fan the pilot light is on Check the three phase input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines 1 Perform the Input Contactor Check the associated leads for loose or faulty connections between the input contactor CR1 the reconnect panel and the main transformer See the Wiring Diagram 3 Perform the CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O amp 9 o o o 2 KH E O x Return to Section TOC Return to Master TOC o O 7 0 v o c x F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The input contactor operates the fan runs the pilot
13. R2 7 5 ohms 100 Watts See Figure F 14 Using 9 16 wrench remove the positive capacitor strap lead and small lead terminal from the positive rectifier plate and output shunt junction See Figure F 10 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O10 Fle S5 o Hie EK SIS ol cc a Return to Section TOC Return to Master TOC F 26 F 26 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 15 HEAT SINK TEST POINTS REMOVE ANY INSULATING PAINT CATHODE SCR 8 Remove any red insulating paint from the heat sink test points See Figure F 15 NOTE Do not disassemble the heat sinks IDEALARC CV 400 LINCOLN B F 27 F 27 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 16 SCR TESTER CIRCUIT AND SCR CONNECTIONS Return to Section TOC Return to Master TOC ANODE swi R2 OE a 6VOLT LANTERN R1 4 ohms 10 watts CATHODE BATTERY SCR AX Gs R2 3 ohms 10 watts UNDER O lO TEST O GATE To test SCRs construct the circuit outlined above Resistor values are plus or minus c E LEADS ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC Glo Ka o x 9 3 lt gt o EE c S 5 9 Construct the circuit shown in Figure F 16 NOTE Be sure the battery is function 2 d One 6 volt lantern battery can be
14. 1000 100 1 4W R77 R158 R159 3 S19400 1501 1 5K 1 4W R78 R79 R81 3 518380 1 PTC THERMI STOR C R88 1 S19400 3322 33 2K 1 4W Oo g R89 R99 2 S19400 4753 475K 1 4W V R90 R94 R 134 R 139 4 S19400 1502 15K 1 4W Die R95 1 19400 2212 22 IK 1 4W oO R112 R113 R114 3 T14648 18 68 5W o R115 R193 2 S18400 1821 1 82K 1 4W olo R141 1 T14648 19 1K_5W R148 1 T12300 68 250 10W cle R149 R150 2 T14650 1 1500 OHMS 15 W R151 1 T14649 11 1607 10W 2 R156 R 157 2 S19400 1372 13 7K 1 4W 5 D R160 R IG 1 R162 R163 R 164 6 S19400 5620 562 1 4W o a R165 tc R169 R170 R171 3 S19400 2000 200 174W R172 R173 R174 3 S19400 2430 243 1 4W R177 R178 R179 R180 R 18 1 13 S19400 6812 68 IK 1 4W R 182 R 183 R 184 R 185 R186 R 187 R 188 R 189 R191 1 19400 4321 4 32K 1 4W R192 1 S19400 2001 2 0K 1 4W SCR 1 SCR2 SCR3 3 15161 19 4 amp 400V SCR X1 X2 X3 3 S15128 4 LM224 OP AMP x4 1 S15128 10 VOLTAGE REF x5 1 S15128 6 VOLTAGE REGULATOR CAPACI TORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED INDUCTANCE HENRYS NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubles
15. Check the welding cables for loose or faulty connections Also make sure cables are sized correctly for the welding current Perform the SCR Diode Recti fier Bridge Test 2 Perform the The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 10 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please observe all safety notes and precautions detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assi
16. Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag e If the PC Board uses protective shorting jumpers don t remove them until installation is complete e f you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow prop er failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all electri cal components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal strips b If the original problem is recreated by the substitution of the original board then the PC boar
17. RECTIFIER ASSEMBLY 205 206 SNUBBER BOARD WITH DIODE OPTION 31 000 MFD 50V EACH 224 Fa 54 EE We H ELECTRICAL SYMBOLS PER 3 E VOLTMETER H K 16 711 T 52s E1537 SWITCH 201 2 J i d 51 225 d Js 2 2081 3 162 NEE 202 k3e 3 gt 2124 31 73 R I i H 12 84 NENNT nie 4 Lie Ji 4 gt 2201 J N A ST J2 i 4 PIN 8 PIN iL 204 5 lt 52054 J3 J1 J2 amp J5 C6 erg 208 RH 6 56 2080 CONNECTOR CAVITY 0047MFD 2 cre i UMBERING SEQUENCE 1400V Ienet i p 213 COMPONENT SIDE OF P C i 240 i 8 H BOARD TS2 i i CONTROL BOARD 8 gt 75 ae Pelee eee eee i NOTES z A CIRCUITRY PRESENT ON F Li TS1 975 r bs CAPACITOR DISCHARGE D mm E ERR CONTROL BOARD ONLY jam 32 CIRCUIT GROUNDING LEAD B TAPE UP SEPARATELY mos Z BREAKER TO PROVIDE AT LEAST L O O e 82A4 600 V INSULATION k i 240 NA C CIRCUIT PRESENT ON a ME e ours YN 51 212 210 211 a ao it DIQUEIORION s 42 ep rT I GROUNDING 32 a o rt 75 f ER Um N D THESE LEADS ARE STUD BE cA erin PRESENT WITH
18. Return to Master TOC O volts 20 volts 5 ms Return to Section TOC Return to Master TOC This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 5 milliseconds in time The machine was loaded with a resistance grid bank The CV 400 meters read 400 amps at 36 VDC Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal O10 O10 Fle S5 o Hie iz SIS ol cc a SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div GOUPIING sanaan DC Trigger u x uuu Internal Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 30 F 30 TROUBLESHOOTING amp REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING NO LOAD CH1 O volts 2 volts 5 ms This is the typical SCR gate pulse voltage waveform The machine was in an open circuit condition no load and operating properly Note that each vertical division represents 2 volts and that each horizontal division rep
19. These terminals are located behind the control panel on the front These devices will give the same control as the output control on the machine Remote Control Adapter Cable K864 A V cable 12 inches 30 m long to connect a K857 Remote Control with a wire feeder control cable 14 pin con nector and the machine 14 pin connector If a remote control is used alone the wire feeder connection is not used See Figure C 1 Capacitor Discharge Circuit K828 1 Mounts inside the CV 400 Recommended when CV 400 is used in conjunction with any LN 23P or older LN 8 or LN 9 semiautomatic wire feeder Eliminates possible arc flash re start of weld when trigger interlock is used Not required with current LN 8 above Code 8700 or LN 9s with serial numbers above 115187 manufactured after 12 83 or any LN 9 having an L6043 1 Power PC Board CV 400 is used with an LN 22 equipped with an older K279 Contactor Voltage Control Option Eliminates electrode overrun when gun trigger is released Not required when later K279 above Code 8800 is used A small spark is objectionable if electrode touches work just after the trigger is released FIGURE C 1 REMOTE CONTROL ADAPTER CABLE K864 STRAIGHT PLUG 14 PIN TO POWER SOURCE CABLE RECEPTACLE 6 SOCKET TO K857 REMOTE CONTROL CABLE RECEPTACLE 14 SOCKET TO L 7 WIRE FEEDER IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Secti
20. ol cc a Return to Section TOC Return to Master TOC Return to Master TOC F 33 F 33 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT continued FIGURE F 17 INPUT CONTACTOR CLEANING AND REMOVAL C T L 3 SIE O L2 T2 O bai Di Eescht C L tnm J X L L J U Je 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL CLEANING PROCEDURE 1 Remove the main input supply power to the machine and remove the input access panel 2 Locate and get access to the input contac tor CR1 in the input box See Figure F 17 3 Remove the input contactor cover plate using a phillips head screwdriver AA WARNING m e Do not apply input power to the machine with the input contactor cover plate re moved 4 Blow out any dirt or dust in or around the contacts with a low pressure air stream 5 Inspect the contacts for signs of excessive wear pitting or contacts fused stuck together a If any of these conditions are present replace the input contactor assembly 6 Replace the input contactor cover plate IDEALARC CV 400 LINCOLN B CONTACTOR REPLACEMENT PROCEDURE 1 Disconnect main input supply power to the machine Locate and get access to the input contac tor CR1 in the input box See Figure F 17 Disconnect the main input supply power leads L1 L2 and L3 to the input contactor
21. su L Observe additional Safety Guidelines detailed in the beginning of this manual IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x B 3 OPERATION GENERAL DESCRIPTION The IDEALARC CV 400 is an SCR controlled three phase input DC output power source for welding It uses a single range potentiometer control The welder s unique combination of transformer three phase hybrid rectifier capacitor bank output choke and solid state control system deliver outstanding per formance RECOMMENDED PROCESSES The IDEALARC CV 400 is a constant voltage power source only It is recommended for all open arc processes including Innershield and all solid wire and gas procedures within its capacity of 60 to 500 amps The CV 400 can be connected to wire feeding equip ment including Automatic wire feeders NA 3 NA 5 and NA 5R Requires the CV 400 Diode Kit option to use the cold start and cold electrode sensing features of these feeders e Semiautomatic wire feeders LN 7 LN 7 GMA INS LN 9 LN 9 GMA LN 22 LN23P LN 25 and LN 742 OPERATIONAL FEATURES AND CONTROLS The following operational controls are standard on the IDEALARC CV 400 Power Source Pilot Light ON OFF Power Tog
22. 475 EJ et e bag 1w g D79 Y Tw R oc ww SUPPLY L ae ay kY t E D51 ox d es Le z 562 AS Y 15V F S D50 et A c20 v set 20V 1 e x gt A ge s o E J2 T e oe 5 204 205 s d D o l METERS re K v e et D83 SIT 5 O 898 203 t a e D12 tc SCR3 gt 7 i a eI rare gt t aR SEH m D15 D18 ul li z 67 _ C19 B i bd 26 LU Ge TK p S 8 562 2 562 ee Ab Ape k owl EJ SE a ZE 100K T oov L D35 204 k D V b T 7 R76 b 7 vj 75 cs D D x3 pon zt Ta A ol FIRING CIRCUIT WE LM224 L224 L224 M _ MIN OUTPUT I IP ax lg BUFFER Y V e e L j Y 10V Control PC Board G2629 1 Schematic G 5 NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes oj uumeg DOL uonoes oj uumeg DOL uonoes oj uumeg DOL uonoes oj uumeg G 6 G 6 ELECTRICAL DIAGRAMS o 3 Snubber PC Board M15370 3 Layout S olg lz els EJE EE EE LN J V o QS Di e IK er eis 1 a N ege 1 oe so a U oN x oo p o o d S ET GE 5 TV
23. F 3 for location If the 120VAC is present and the contactor 4 Connect an AC voltmeter to the leads does NOT activate then the input contactor is faulty Replace the input contactor WARNING Electric Shock can kill Return to Section TOC Return to Master TOC e With the input power on there are high voltages inside the machine Do not reach into the machine or touch any internal part of the machine while the power is on Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 Fle EIE o Hie EK SIS ol cc a Return to Section TOC Return to Master TOC Return to Master TOC F 15 F 15 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 4 INPUT CONTACTOR TEST CONNECTIONS 0597 D Dll KD E 9106 90755 184 LINCOLN ELECTRIC CO CRI m 12161 61 E S g 38 3 z amp M en TEST FOR CONTACT CONTINUITY 1 Disconnect the main input supply power to the machine Remove the two leads connected to the input con tactor coil 233 and X1 232 See Figure EA for location Using the external 120VAC supply apply 120VAC to the terminals of the input contactor coil If the con tactor does NOT activate the input contactor is faulty Replace the input contactor APPLY EXTERNAL 120 VAC HERE
24. GUIDE RECOMMENDED COURSE OF ACTION 1 Check the Output Control switch S2 and associated wiring See the Wiring Diagram Check feedback leads 220 204 205 and 206 for loose or faulty connections 3 Perform the SCR Diode Rectifier Bridge Test 4 The control board may be faulty Replace Check the Output Control R4 and associated wiring See the Wiring Diagram Check the Output Control switch S2 and associated wiring See the Wiring Diagram 3 Perform the 4 Perform the SCR Diode Rectif ier Bridge Test 5 The control board may be faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O amp 9 o o o 2 KH E O x Return to Section TOC Return to Master TOC Q O E 7 x 3 o x F 7 F 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine does not have maxi mum output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Make sure the correct three phase
25. METER J de II IKAW 231 OPTION ONLY 2 GUT We ums o GREEN OUTPUT CONTROL CONTROL FRAN a SWITCH BACH I 224 a 12 9 94F OPTIONAL O L9270 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine IDEALARC CV 400 LINCOLN ELECTRIC ELECTRICAL DIAGRAMS elo Control PC Board G2629 1 Layout m Oja gt ol o c c ITEM REQ D PART No IDENTIFICATION 5 5 C 1 C2 C3 C24 C36 C4 1 C44 7 13490 25 4 7 35 C4 C5 C6 3 S13490 96 157200 Oo O C7 C8 C9 C 10 C11 C 12 C17 11 S16668 5 022750 CID C18 C19 C30 C31 C15 C20 C22 3 13490 18 1 8720 C23 1 S13490 108 157 100 C35 1 13490 98 33 50 C37 C38 2 S13490 102 0477 100 C39 1 13490 66 47 35 C40 C43 2 T11577 2 150 50 C45 1 T11577 52 0047 or 0057 1400 C46 1 S16668 11 1750 D 1 D2 D3 D4 05 D6 D7 D8 D9 51 T12199 1 1N4004 D 10 D11 D 12 013 014 D 15 D 16 017 D 18 D22 023 031 D32 D33 D34 D35 D
26. QI e 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR 3 RECONNECT PANEL JUMPER LINKS IDEALARC CV 400 LINCOLN B A 6 INSTALLATION RECONNECT PROCEDURE Multiple input voltage welders are shipped from the fac tory connected for the highest voltage listed on the machine s rating plate Before installing the welder be sure the reconnect panel is connected for the proper OUTPUT CONNECTIONS CONNECT ELECTRODE AND WORK LEADS TO OUTPUT TERMINALS The output welding cables are connected to the out put terminals marked and These 1 2 terminals are located at the lower right and lower left corners of the front panel See Figure A 5 See Table A 1 for recommended cable sizes for com bined lengths of electrode and work cables voltage Return to Section TOC Return to Master TOC Failure to follow these instructions can cause immedi ate failure of components in the welder To reconnect a multiple voltage machine to a different voltage remove input power and change the position of the jumper links on the reconnect panel Follow the input connection diagram located on the inside access panel cover appropriate for your machine s input volt age This same connection diagram is shown in Figure A 4 below FIGURE A 4 INPUT CONNECTION DIAGRAM FOR 230 460 VOLTS AC 50 60 HZ o O 2 o 8 x E 2 x Return to Master TOC A WARNING HIGH VOLTAGE CA
27. Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x E 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE AA WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunc tions Simply follow the three step procedure list ed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into two main categories Output Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted
28. WELD DESCRIPTION This test will determine if the correct voltages are being applied to the primary windings of the Main Transformer T1 and induced on the secondary winding auxiliary windings and phase angle windings Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter 5 16 Nut driver IDEALARC CV 400 wiring diagram See the Electrical Diagrams section of manual olo O o Fle S n o G AIS SIS mlt 3 2 ol cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 17 F 17 TROUBLESHOOTING amp REPAIR olo Ele MAIN TRANSFORMER T1 VOLTAGE TEST continued Led o g HE lz FIGURE F 5 INPUT CONTACTOR RECONNECT PANEL AND PRIMARY LEADS g TO MAIN TRANSFORMER LOCATIONS E HE eic INPUT SUPPLY INPUT RECONNECT CABLE ENTRY CONTACTOR PANEL OPENING CR1 ASSEMBLY MAIN TRANSFORMER LEADS O lO H O o H Fle x H 212 9 d 2 8 8 E E z CASE BACK SIDE VIEW c cc TEST PROCEDURE 1 Set the ON OFF power switch to OFF 5 Connect main input supply power to the TP machine 2 Disconnect main input supply power from the machine 6 Set the ON OFF power switch to ON e e 3 With the 5 16 nut driver remove the case a Make sure the input contactor CR1 F top and sides and the reconnect panel energizes and the fan runs 9 cover 7 Test with an AC voltmeter for p
29. cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larger insulated wire Tape the bolted connection with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose c Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to the work cable for ease of use NOTE Using the extended 21 lead eliminates the need to use the LN 9 s remote work lead accesso ry which has a direct work lead jack Connect the LN 9 wire feeder control jumpers on the Voltage Control board See LN 9 operator s manual NOTE The connection diagram shown in Figure C 5 shows the electrode connected for positive polarity To change polarity a Set the CV 400 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative out put terminal c Move the work cable to the positive output terminal d Set the VOLTMETER toggle switch on power source to negative e Set the voltmeter toggle switch on feeder if equipped to match electrode polarity FIGURE C 5 LN 8 OR LN 9 WIRE FEEDER CONNECTION TO THE IDEALARC CV 400 LN 8 ORLN 9 WIRE FEEDER TERMINAL CONTROL CABLE STRIPS lt TO z INPUT 21ls S CABLE r 1S S GND 26 21 BLANK S e 4 3119 2 32 S KN _ 32 7 8 76S S 75 7s 76 EL
30. driver 9 16 Wrench IDEALARC CV 400 wiring diagrams See the Electrical Diagrams section of this manual olo O o Fle S n o G AIS SIS mlt 3 2 ol cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 9 o o o 2 KH E O x O O E 8 o v o c x F 22 F 22 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 9 CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS G2629 CV 400 CV 500 CONTROL 203 TEST PROCEDURE 14 Disconnect the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Disconnect the welding cables from the welding output terminals Locate and remove molex plug P3 from the control board See Figure F 9 M15370 SNUBBER Locate and remove molex plug P5 from the snubber board See Figure F 9 Locate and remove lead 204 from resistor R2 7 5 ohms 100 watts See Figure F 14 Using the 9 16 wrench remove the positive capacitor strap lead and small lead terminal from the rectifier plate and output shunt junc tion See Figure F 10 FIGURE F 10 CAPACITOR STRAP LEAD CONNECTIONS POSITIVE CAP
31. etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 IDEALARC CV 400 LINCOLN B Return to Mast
32. etus Eta eed ena SeeeEA unn A 5 RECONNMECE PrOCCCUIC E A 6 Output ln Ee e EE A 6 Connect Electrode and Work Leads to Output Terminals sse A 6 Connect Wire Feeders secret te tene EH REY Kia s a aa RR iere ga XE aas ER dkk akad A 8 Return to Master TOC o O E E 7 c x E o x Return to Master TOC IDEALARC CV 400 LINCOLN A 2 A 2 INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC CV 400 INPUT THREE PHASE ONLY Standard Voltage Input Current at Rated Output 230 460 77A 39A 400A 36V Return to Section TOC Return to Master TOC RATED OUTPUT Duty Cycle Welding Output Volts at Rated Amps 100 400 36 60 450 38 50 500 40 OUTPUT Current Voltage Maximum Open Auxiliary Range Range Circuit Voltage Power Return to Section TOC Return to Master TOC 60 500 Amps 12 42 Volts 46 VDC 115 VAC 10 Amps 42 VAC 10 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES Fuse Type 75 C Type 75 C Input Voltage Input Amps Super Lag Copper Wire in Copper Ground Frequency Rating on or Breaker Conduit AWG Wire in Conduit Volts Hz Nameplate Size IEC Sizes AWG IEC Sizes 230 77 125 3 27 mm 6 13 mm 460 39 60 8 8 4 mm 10 5 3 mm PHYSICAL DIMENSIONS Height Width Depth Weight 27 5 in 699 mm 22 2 in 565 mm 32 0 in 813 mm 357 lbs 162 kg olo O o E it C els ois ele bi cc a No adde
33. from vaporizing on localized Electric and Magnetic Fields EMF Welding contact with hot engine parts and igniting Do current creates EMF fields around welding cables and not spill fuel when filling tank If fuel is spilled welding machines wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Keep all equipment safety guards covers and before welding devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equip ment Exposure to EMF fields in welding may have other health effects which are now not known Q O Lr E 2 7 E x E o x All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 1 e In some cases it may be necessary to remove safety 2 d 1 Route the electrode and work cables together Secure guards to perform required maintenance Remove them with tape when possible guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 2 Never coil the electrode lead around your body Always use the greatest care when working near moving parts 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on you
34. in good condition 1 Disconnect power supply lines to the machine before performing periodic maintenance 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot Periodically blow out dust and dirt from the inside of the machine with a low pressure air system Be sure to clean the following components thoroughly See Figure D 1 for their location Main transformer Output studs Polarity switch Rectifier assembly Control box assembly 3 Dirt and dust may also accumulate on the remote control terminal strips Wipe or blow off the terminal strips regularly especially in damp locations 4 nspect the welder output terminals and control cables for fraying cuts and bare spots 5 The fan motor has sealed ball bearings and requires no maintenance IDEALARC CV 400 LINCOLN B D 3 SE 5S A MAINTENANCE FIGURE D 1 Major Component Locations IDEALARC CV 400 LINCOLN E 8 d 2 2g Zub Bu AEQ SZ CO oz GEZ m o uc Zul Z wy qx Orat Ganz ror Of 06056 HL 5m mruaot m umb Ess ukuz2 oQotctzzZomiocoz lt lt 2 O lt Z O i lt lt lt mooozooouomcorc Q DEE a rT NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes oj uumeg DOL uonoes oj uumeg DOL uonoes oj uumeg DOL uonoes oj uumeg D 4 NOTES IDEALARC CV 400 LINCOL
35. only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn STOP ON O QO OOD Assembly now has the proper clamping force 9 Perform the Active SCR Test AFTER REPLACING THE SCRs Follow the steps in the SCR Diode Rectifier Removal and Replacement procedure to reassemble the machine CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn Tighten first cap screw 1 8 turn Tighten second cap screw 1 8 turn STOP D O QO CQ nm Assembly now has the proper clamping force 9 Perform the Active SCR Test IDEALARC CV 400 LINCOLN B F 44 F 44 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS Return to Section TOC Return to Master TOC AA WARNING Service and repair should be pe
36. sec ondary windings are connected to the rectifier bridge assembly In addition the main transformer has sepa rate and isolated 115VAC and 42VAC auxiliary wind ings The 115VAC is available at the terminal strip and the 14 pin amphenol and is protected by a 10 amp cir cuit breaker The 42VAC is available at the 14 pin amphenol only and is also protected by a 10 amp cir cuit breaker The three 21VAC phase angle windings are also housed in the main transformer assembly These windings provide power and timing for the con trol board NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o E it C 8 8 ois ele ES cc a Return to Section TOC Return to Master TOC Return to Master TOC E 3 E 3 THEORY OF OPERATION FIGURE E 3 OUTPUT CONTROL RECTIFICATION AND FEEDBACK OUTPUT CONTROL CONTROL TRANSFORMER MAIN TRANSFORMER dMomzzoomz INPUT CONTACTOR REMOTE CONTROL CONTROL BOARD 14 PIN AMPHENOL OUTPUT CONTROL RECTIFICATION AND FEEDBACK The three phase AC output from the main transformer secondary is rectified and controlled through the SCR diode bridge Output current and voltage is sensed at the shunt and output capacitors respective ly This feedback information is processed in the con trol board The cont
37. to the front panel lead 225 to the negative output lead and lead 224 to the positive output lead Connect plug P5 to the snubber board and plug P3 to the control board Connect the choke and negative capacitor lead to the left side of the negative heat sink plate See Figure F 19 Apply a thin coating of Dow Corning 340 heat sink compound Lincoln E1868 to connection points Connect the positive capacitor lead and shunt to the positive heat sink plate See Figure F 19 Install the glastic stiffeners to the left and right sides See Figure F 19 Apply a thin coating of Dow Corning 340 heat sink com pound Lincoln E1868 to connection points Install the case top and sides Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 38 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT A WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedure
38. volts AC is available at pins A and J Domestic and Export models only 42 volts AC is available at pins and K On the terminal strip 115 volts AC is available at terminals 31 and 32 42 volts AC is not available at the terminal strip The two circuits 115 volts AC and 42 volts AC are isolated and each is protected by a 10 amp circuit breaker FRONT VIEW OF 14 PIN CONNECTOR RECEPTACLE K 42 A 32 LEAD NO FUNCTION 32 115 VAC GND Chassis Connection Trigger Circuit Trigger Circuit Output Control Output Control Output Control Work Connection 42 VAC 115 VAC 42 VAC A B C D E F G H l J K L M N IDEALARC CV 400 LINCOLN B B 8 NOTES IDEALARC CV 400 LINCOLN NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes oj uumeg Section C 1 Section C 1 TABLE OF CONTENTS o F ACCESSORIES 5 ACCOSSOLIOS eege Section C deele E te EE C 2 g dell Ee LTE C 2 E Factory Installed Optons enne nn tenens innen C 2 Field Installed Options u L L uu aaa Ea aa a auqa ag a C 2 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders C 3 Automatic Wire Feeders NA 3 NASA C 3 Semiautomatic Wire Feeders LN 7 LN 8 UNO C 6 Return to Master TOC o O E E 7 c x E o x Return to Master TOC IDEALARC CV 400 LINCOLN Return
39. with a heavy accessory such as a trailer or a gas cylinder Lift only with equipment of adequate lifting capacity Be sure the machine is stable when lifting Do not stack more than three high Do not stack the CV 400 on top of any other machine The IDEALARC CV 400 weighs 357 pounds 162 kilo grams A permanent lift hook is located at the top of the machine positioned at the center of gravity for sta ble lifting STACKING IDEALARC CV 400s may be stacked three high The bottom machine must be on a stable hard level sur face capable of supporting the weight of up to three machines 1071 pounds 486 kilograms Be sure that the two holes in the top front corners of the bottom machine line up with the holes in the base rails of the machine above Fasten the machines together with 5 16 bolts lockwashers and nuts through these holes The lift hook is positioned so that it fits without interfer ence under the base of the second machine TILTING Place the machine on a secure level surface Any sur faces you place it on other than the ground must be firm non skid and structurally sound ELECTRICAL INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the case front control panel See Figure A T Input supply line entry is through a hole in the case rear top panel A removable door covers the input connec tion box which contains the i
40. 0 O10 Fle S5 o Hie EK SIS ol cc a Return to Section TOC Return to Master TOC Return to Master TOC F 47 F 47 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 25 LIFT BAIL REMOVAL a 2 MOUNTING BOLTS 4 V l d CAPACITOR STRAPS REMOVAL OF LIFT BAIL 1 Remove the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Remove the two fiber baffles from the left and right sides of the lift bail adjacent to the main transformer See Figure F 25 Remove the two leads 220 and 204 from resistor R2 7 5 ohms 100 watts Remove the positive capacitor strap from the output shunt Remove the negative capacitor strap from the negative rectifier plate Remove the sheet metal screw that holds the capacitor bank assembly to the case back This should enable the capacitor bank to be removed with the lift bail assem bly CAPACITOR BANK CASE BACK MOUNTING SCREW LIFT BAIL TRANSFORMER IRON MOUNTING BOLTS 4 8 Using the 9 16 socket wrench remove the four bolts left and right mounting the lift bail to the transformer top and bottom irons 9 Using the 9 16 socket wrench remove the four bolts flat washers and lock washers mounting the lift bail assembly to the base of the machine The transf
41. 37 D40 D4 1 D42 D47 048 D49 D50 D51 D52 D55 D62 D63 D65 D66 D67 D74 D75 D76 D77 D78 D79 D80 D8 1 D82 D83 D19 D20 D2 1 068 D69 D70 S TI2188 4 TN4005 DIODE O Oo e D7 1 D72 D73 O lO 62629 7 CV400 CV500 I CONTROL p D72 073 075 4 ee 28 ares F DZ 10 1 T12702 33 1N53478 DZ 12 1 T12702 40 1N4735 NK DZ13 1 T12702 23 IN53828 V DZ 14 1 T12702 41 1N5359B ZENER DI ODE o Ji J2 2 S18248 8 HEADER J3 1 S18248 4 HEADER o OCI I 1 15000 10 OPTO ISOLATOR olo 02 1 T12704 54 N CHANNEL FET SS Sis 08 1 T12704 36 2N4857 c QU1 0U2 GUS 3 T12707 4 2N6027 EIS Ri R2 R3 3 T1231 14 27 1 2W 513 R4 R5 R6 R7 R8 R9 R 146 8 818400 2671 2 67K 174W _ s gt mer R 154 R10 R35 R86 R87 4 S19400 4750 475 1 4W D R11 R 12 R13 R29 R30 R31 13 _ S19400 1003 100K 174W R5 1 R56 R57 R59 R137 R153 R175 R14 R 15 R 16 R76 R 166 R167 7 819400 2870 267 174W R168 R17 R 18 R 19 R82 R93 5 S19400 4751 4 75K R20 R2 1 R22 R60 R63 R 190 6 S19400 1001 IK 1 4W R26 R27 R28 R38 4 T10812 39 5OK 1 2W TRIMMER R36 R43 2 S19400 1500 150 1 4W R37 R62 R 135 R 155 4 S19400 2213 221K 1 4W R39 1 S19400 4322 43 2K 1 4W R40 R41 2 T12732 10 2 7 W K R50 R58 R61 3 19400 2211 2 21K 1 4W R64 R83 R91 R98 R 124 R 140 11 S19400 1002 10K 1 4W R142 R143 R144 R 145 R176 R70 1 S19400 1212 12 IK 1 4W Olio R71 1 T10812 41 10K 1 2W TRIMMER O Oo R75 R152 2 19400
42. 7 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or d
43. 9 Test with an AC voltmeter for proper main tests are incorrect check for loose or SIE input supply voltage from the output side of faulty connections als the input contactor CR1 See the Wiring O Q z b If the connections are good then the tc 3 Diagram ane igure des main transformer may be faulty Re a T1 to T2 place the main transformer b T2 to T3 c T1 to T3 10 Read the meter a If proper voltage is present for all three phases the input contactor is working properly b If the proper voltage is not present for any or all of the three phases the input contactor may be faulty Replace the input contactor Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle S n o G AIS SIS mlt 3 2 ol cc a Return to Section TOC Return to Master TOC Return to Master TOC F 19 F 19 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 7 PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION N Q O o O Q O 12 O TERMINAL STRIP AMPHENOL From To Terminal Strip Terminal Strip Lead 31 Lead 32 115 Amphenol PinK Lead 42 Amphenol Pin Lead 41 42 12 Test for 115VAC between leads 31 a
44. ACITOR STRAP LEAD SMALL LEAD TERMINAL Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 23 F 23 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 11 HEAT SINK AND SCR TEST POINTS REMOVE ANY INSULATING PAINT 8 Remove any red insulating paint from the heat sink test points See Figure F 11 NOTE Do not disassemble the heat sink Measure the resistance from the anode to the cathode of SCR 1 using an analog volt ohmmeter multimeter set at R x 1000 scale See Figure F 11 a Reverse the meter leads and measure the resistance from the cathode to the anode of SCR 1 See Figure F 11 b If a low resistance is measured in either meter polarity SCR 1 is faulty Replace SCR 1 Test the resistance of SCR 2 and SCR 3 using the same procedure described in Step 9 Measure the resistance of diode D1 from anode probe to cathode probe using an analog ohmmeter set at R x 1000 scale The resistance should be low See Figure E11 IDEALARC CV 400 LINCOLN B CATHODE SCR a Reverse the meter leads and measure the resistance from cathode probe to anode pr
45. E O x Return to Section TOC Return to Master TOC o O 7 0 v o c x TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The output terminals are always electrically hot POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Remove any external leads that may be connected to the 14 pin amphenol or the terminal strip If the problem disappears the fault is in the control cable or wire feeder TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Check for an internal short between leads 2 and 4 See the Wiring Diagram Remove plug J3 SCR gate leads from the control board If the problem disappears the control board may be faulty Replace If the output terminals are still electrically hot perform the SCR Diode _ Rectifier Bridge Test 3 The snubber board may be faulty Check or replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O amp 9 o o 2 x E O x Return to Section TOC Retu
46. ED An SCR tester as specified in this procedure 5 16 Nut driver 9 16 Wrench IDEALARC CV 400 wiring diagrams See the Electrical Diagrams section of this manual O10 O10 Fle S5 o Hie iz SIS ol cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 9 o o o 2 x E O x Return to Section TOC Return to Master TOC o O 7 O v o c x F 25 F 25 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 12 CONTROL BOARD PLUG P1 AND P3 LOCATIONS G2629 CV 400 CV 500 1 CONTROL 203 FIGURE F 13 SNUBBER BOARD PLUG P5 LOCATION M15370 SNUBBER FIGURE F 14 RESISTOR R2 LOCATION TEST PROCEDURE 1 Disconnect the main input supply power to the machine 2 With the 5 16 nut driver remove the case top and sides Remove the screws holding the front panel and lower the panel 3 Disconnect the welding cables from the welding output terminals 4 Locate and remove molex plug P3 from the control board See Figure F 12 IDEALARC CV 400 LINCOLN Locate and remove molex plug P5 from the snubber board See Figure F 13 Locate and remove lead 204 from resistor
47. F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES AA WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems when troubleshooting and replacing PC boards please use the following procedure 1 Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static elec trical damage and electrical shock Read the warn ing inside the static resistant bag and perform the following procedures A ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations Reusable Container Do Not Destroy PC Board can be damaged by static electricity Remove your body s static charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame f you don t have a wrist strap touch an unpainted grounded part of the equipment frame
48. IDEALARC CV 400 For Machines with Code Numbers 10084 thru 10087 Return to Master TOC View Safety Info Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be in creased by proper installation and thoughtful operation on your 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 Return to Master TOC View Safety Info o gt 2 D o z 2 gt o O HE x n v o lt c x 5 x SERVICE MANUAL LINCOLN amp World s Leader in Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors Sales and Service through subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 Return to Master TOC View Safety Info SAFETY A WARNING 5 CALIFORNIA PROPOSITION 65 WARNINGS A d Diesel engine exhaust and some of its constituents The engine exhaust from this product contains z are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm a The Above For Diesel Engines The Above For Gasoline Engines
49. LTMETER OPTIONAL Displays actual out input power is still applied put voltage 10 42 VAC AUXILIARY CIRCUIT BREAKER This 10 6 DC AMMETER OPTIONAL Displays actual output amp breaker protects the 42 VAC auxiliary circuit current 11 115 VAC AUXILIARY CIRCUIT BREAKER This 10 amp breaker protects the 115 VAC auxiliary circuit Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 Fle s s Ri Hie iz SIS ol cc a Return to Section TOC Return to Master TOC Return to Master TOC B 6 OPERATION WELDING OPERATION LOCAL CONTROL The following procedures are for using the CV 400 in the local control mode of operation For remote control of the machine see the Remote Control section Before operating the machine make sure you have all materials needed to complete the job Be sure you are familiar with and have taken all possible safety precau tions before starting work It is important that you follow these operating steps each time you use the machine 1 Turn on the main AC input power to the machine 2 Set the VOLTMETER or switch to the appro priate position Set toggle to Electrode Negative position if the electrode is connected to the negative output ter minal Set toggle to Electrode Positive position if the elec trode is connected to the positive output termi
50. N DOL Jeep 0 LUS DOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes oj uumeg Section E 1 Section E 1 TABLE OF CONTENTS o THEORY OF OPERATION SECTION Theory of Operation a ERR Re Orga duas Section E 2 General Descriptio EE E 1 5 Input Line Voltage Contactor and Main Transformer aaaaaaaaaaasaaaassaaasnansnnnsnnnnsannnaaana E 2 c Output Control Rectification and Feedback E 3 Protective Devices and Circuits aaaaaaaaansaaansaannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnsaansananaaaaa E 4 Sel Een Me E 5 FIGURE EI BLOCK LOGIC DIAGRAM OUTPUT CONTROL CONTROL TRANSFORMER NEGATIVE OUTPUT TERMINAL MAIN TRANSFORMER Return to Master TOC domzzoomzagm AOP UOommm e TERMINAL SCR DIODE HYBRID BRIDGE INPUT CONTACTOR REMOTE CONTROL CONTROL BOARD o O E E 7 c x E o x 14 PIN AMPHENOL GENERAL DESCRIPTION The CV 400 is an SCR controlled three phase DC power source It is designed for all open arc constant voltage CV processes within the capacity of the machine The output characteristics have been opti mized for CV processes without the use of a variable arc control Minimum to maximum output is obtained with a single potentiomete
51. N KILL DUAL VOLTAGE MACHINE S Do not operate with covers Do not touch electrically live parts INPUT SUPPLY CONNECTION DIAGRAM gt kashas PE e IMPORTANT CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS e Disconnect input power before e Only qualified persons should install servicing us or service this equipment NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS 2 CONNECTION FOR HIGHEST RATING PLATE VOLTAGE 50 OR 60 HZ LINK 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX L3 o w ent Te o ea 2 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LINES 1 LEAST 600 VOLT INSULATION INPUT L2 70 X o o 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS L1 pras S TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN obo 4 CONNECT TERMINAL MARKED CTO GROUND PER LOCAL AND NATIONAL ELECTRIC O lO GND vs HI T CODES OO A a KE 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS Ge PILOT DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE Ska TRANSF USE SECURE THE REMAINING HEX NUTS IN PLACE o Blt CONNECTION FOR LOWEST RATING PLATE VOLTAGE 50 OR 60 HZ B5 o LINK 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX o L3 w R o oo lo d 2 DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT o 2 LINES sv o LEAST 600
52. O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x ACCESSORIES SEMIAUTOMATIC WIRE FEEDERS CONNECTING THE LN 7 TO THE IDEALARC CV 400 TERMINAL STRIP 1 Set the CV 400 POWER toggle switch to the OFF 0 position 2 Disconnect main AC input power to the CV 400 3 Connect the wire feeder control cable leads to the CV 400 terminal strip as shown in Figure C 4 a Make a bolted connection using AWG 14 or larg er insulated wire Tape the bolted connection with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose c Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to the work cable for ease of use 4 Connect the wire feeder control cable ground lead io 6 Set voltmeter toggle switch to match electrode polar the frame terminal marked 77 NOTE The CV 400 must be properly grounded 5 PERFORM THIS STEP ONLY IF THE LN 7 IS EQUIPPED WITH A METER KIT NOTE If the work cable length is less than 25 feet and the connections to the work piece are secure then wire feeder control cable lead 21 can be con nected directly to the CV 400 terminal strip Extend wire feeder control cable lead 21 so it can be connected directly to the work piece ity NOTE The connection diagram shown in Figure C 4 shows the electro
53. O o E F E o G iz SIS ol cc a Return to Section TOC Return to Master TOC Return to Master TOC FIGURE F 28 COIL LEAD PLACEMENT MACHINE FRONT SECONDARY COIL LEADS P4 3 Install the bottom primary coils one on each of the three legs of the bottom iron assembly The coils must be in correct position left center right Place the coils so that the leads come out at the back of the machine See Figure F 28 for proper positioning 4 Place insulation Lincoln Electric part number S20728 on top of each of the three primary coils The longer side of the insulation should be placed toward the front of the machine See Figure F 29 for the location of this insulation 5 Place the three secondary coils on top of the insu lation installed in Step 4 The leads should come out at the front of the machine with the short leads on top See F 28 for proper positioning 6 Insert shims Lincoln Electric part number CI001250 or C1000317 between the secondary coil sides and the iron assembly on either side of the legs See Figure F 29 PRIMARY COIL LEADS 7 Place insulation Lincoln Electric part number S20728 on top of each of the three secondary coils The longer side of the insulation should be placed toward the front of the machine where the secondary start and finish leads come out See Figure F 29 8 Install the three top primary coils noting which is right left
54. Remove the control transformer primary leads H1 H2 or H3 dependent on input volt age from L1 and L3 terminals on the input side of the contactor Using the 7 16 socket wrench disconnect the output leads T1 T2 and T3 from the input contactor Label the leads Identify and label the leads connected to the input contactor coil See the Wiring Diagram Disconnect the leads from the input contac tor coil leads X1 232 and 233 See the Wiring Diagram Remove the three self tapping mounting screws using a 5 16 socket wrench See Figure F 17 8 Remove the input contactor 9 Insert the replacement input contactor and install it following the procedures in reverse order NOTE Be sure to reconnect all leads correctly Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 34 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detaile
55. TED ALLIGATOR CLIP INPUT CABLE CONTACTOR CR1 besse C CASE BACK 7 Read the meter for 115VAC a If 115VAC is present the control trans former is functioning properly b If 115VAC is NOT present go to Step 8 8 If 115VAC is not present between leads X1 and 231 check the spliced connection between 231 and X2 Test for correct main input supply power to the control transformer primary windings H1 H2 H3 etc Check the main input supply power hookup to the machine See the Wiring Diagram a If the correct main input supply power to the control transformer primary windings is present AND the secondary voltage is not correct the control transformer may be faulty Replace IDEALARC CV 400 LINCOLN F 13 F 13 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing
56. VOLT INSULATION INPUT CONTACTOR 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS g g Li c_u 9 34 63 o TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN s s GND H1 4 CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC D m H2 H3 e CODES o tc e mor 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS D TRANSF THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B A 7 INSTALLATION olo O19 FIGURE A 5 ele OUTPUT TERMINAL CONNECTIONS OO olg iz DAP SIE HE C J K U WAWA MIKU Crrrrrrrrr kb e e Ne Ne N M ddddddddda rrrrrr Ww Ww In Bon bon Rer 1 NEGATIVE WELDING CABLE CONNECTION o O E E 9 o o o o 2 POSITIVE WELDING CABLE CONNECTION x Return to Master TOC TABLE A 1 CABLE SIZES FOR COMBINED LENGTH OF ELECTRODE AND WORK CABLE di MACHINE LOAD N 400A 500A 318 100 DUTY 50 DUTY E Ir CABLE LENGTHS CYCLE CYCLE SIS UP TO 50 ft 3 0 2 0 o 15 m 85 mm 67 mm d 2 2 50 to 100 ft 3 0 2 0 E 5 15 to 30 m 85 mm 67 mm t o cc 100 to 150 ft 3 0 3 0 30 to 46 m 85 mm 85 mm 150 to 200 ft 3 0 3 0 46 to 61 m 85 mm 85 mm 200 to 250 ft 4 0 4 0 V 67 to 76 m 107 mm 107 mm i Return to Section TOC Return to Master TOC
57. X1 232 AND 233 LEAD TERMINALS F AH ACC730 80258 d 4 With the contactor activated check the continuity across the contacts Zero ohms or very low resis tance is normal See Figure EA If the resistance is high the input contactor is faulty Replace the input contactor 5 When the contactor is NOT activated the resistance should be infinite or very high across the contacts If the resistance is low the input contactor is faulty Replace the input contactor IDEALARC CV 400 LINCOLN B F 16 F 16 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshoot ing assistance before you proceed Call 216 383 2531 or 1 800 833 9353
58. and remove the diode that is to be replaced 4 Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool DO NOT SCRATCH THE DIODE MOUNTING SURFACE 5 Polish each heat sink s mounting surface using No 000 fine steel wool Wipe the sur face clean with a lint free cloth or paper towel 6 Inspect the mounting surfaces of each new diode Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the diode mounting surface 7 Apply a thin 0 003 to 0 007 uniform layer of E1868 Dow Corning 340 heat sink com pound to the heat sink mounting surface Return to Section TOC Return to Master TOC a Do not apply compound to the diode stud or mounting threads b The diode threads must be clean and free of defects so that the nut can be fin ger tightened before applying torque A slip type torque wrench must be used to tighten the diode nut 8 Tighten the diode nuts to the specifications in the following table O10 O10 Fle S5 o Hie EK SIS ol cc a a Start the nuts for diodes with steel studs by hand and then torque them accord ing to the following table b Run the nuts for diodes with copper studs on all the way by hand then torque them according to the following table c Turn the nuts a minimum of 1 2 turn more while torquing 9 Install the case top and sides Return to Section TOC Return to Mast
59. and center Leads should come out at the back of the machine See Figure F 28 for prop er positioning The coils must be in correct position left center right 9 Install the top iron lamination and choke assem bly With the 9 16 deep well socket wrench reassemble the four thru bolts that clamp the top E iron to the bottom E iron Lightly tap on the top of the iron with a hammer before tightening Tighten the nuts and thru bolts to 19 25 Ib ft FIGURE F 29 COIL INSULATION PRIMARY COILS TOP LEFT TOP CENTER TOP RIGHT SECONDARY COIL ASSEMBLY INSULATION PRIMARY COIL BOTTOM SHIMS IDEALARC CV 400 LINCOLN B F 51 F 51 TROUBLESHOOTING amp REPAIR O10 ele MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued x oak FIGURE F 30 PRIMARY THERMOSTAT LOCATION a 2 2 E E SE TOP VIEW lo EC C THERMOSTAT O10 ae S E IK FRONT VIEW ele cle 5 5 cc 10 Mount the primary thermostat to the lead 11 If necessary trim off excess secondary lead end coil nose See Figure F 30 Place a stickout and TIG weld the leads together small amount of Lincoln Electric E1603 See Figure F 31 Epoxy between the coil nose and the coil insulation and between the insulation and the thermostat Hold the thermostat in place with E2381 375 wide tape If nec essary after assembly protect the thermo stat te
60. assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will determine if the input contactor is receiving the correct coil voltage and if the con tacts are functioning correctly Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt ohmmeter Multimeter 5 16 Nut driver IDEALARC CV 400 wiring diagrams See the Electrical Diagrams section of this manual External 120VAC supply olo O o Fle 58 n o G iz g 9 e E 3 2 ol oO EC x Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN F 14 F 14 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 3 INPUT CONTACTOR CONNECTIONS o O 9 o o c x 5 E tc Return to Master TOC O10 P S K olg a gt D I E E SIE JE TEST PROCEDURE 5 Apply the correct voltage to the machine and SS turn the power switch S1 ON 1 Disconnect the main input supply power to the machine 6 Check for 120VAC at the contactor coil leads 2 With the 5 16 nut driver remove the case If the 120VAC is NOT present with the power top and the reconnect panel cover switch S1 on check the power switch S1 and associated circuitry See the Wiring 3 Locate the two leads connected to the input Diagram Also perform the contactor coil 233 and X1 232 top See Transformer T2 Voltage Test Figure
61. at sink plate See Figure F 19 Remove the gate leads from the control board plug P3 Remove plug P5 from the snubber board Also remove lead 224 from the positive output lead Remove lead 225 from the negative output lead Remove the green ground lead from the front panel Remove the three heavy aluminum sec ondary leads from the SCR finned heat sinks Remove the four nuts and associated wash ers that hold the SCR diode assembly to the mounting brackets Carefully lift and remove the SCR diode heat sink assembly from the machine Note It may be necessary to loosen the four sheet metal screws that hold the front panel to the base Carefully lift and pull out the front panel to allow clearance for SCR diode 12 18 14 15 16 17 18 19 20 IDEALARC CV 400 LINCOLN B Ro assembly removal Clear any necessary leads that might hinder removal For reassembly carefully place the SCR diode assembly into position on the mount ing bracket and reinstall the washers and nuts Tighten the front panel to base if it was loosened earlier Replace and tighten the four nuts and lock washers that hold the SCR diode assembly to the mounting brackets Reattach the three heavy aluminum sec ondary leads to the SCR finned heat sinks Apply a thin coating of Dow Corning 340 heat sink compound Lincoln E1868 to con nection points Connect the green ground lead
62. ch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 IDEALARC CV 400 LINCOLN B MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Eri m M i i v InStallatiOn MEE Section A Technical SpeciticationSsi 4 ssnA PER A 2 Safety Precautions ccccceesccececeeceeeeeceaeeeeeaeeseaaeeeeaaaeeeeaeeeeaaaesgeaeeecaaaeseaeesseaaeseseeeeseaeeeeeeseennees A 3 Location and VentilatiOni i aee a ee Rente ta are ees ded ex debs desee Rue eR A dg vegans ane ERR deed A 3 Electrical Input CONNECTIONS enne KALT ORA HAK A RAR DARK enne nnns nennen A 3 Reconnect Procecdure esee r A 6 OUTPUT COMMECHONS ee A 6 iru mE Section B Salely ud 5167 1011010 0 MEER B 2 General Description ae caderet cider Sate da sa Ced dt da co EET naan aar B 3 Controls and Settings PEE B 5 W lditig ele E Le ET B 6 Overload Protection ET B 7 Auxiliary POW E B 7 ACCOSSOMIOS m Section C enee C 2 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders C 3 MAINTOMAN CO uuu E
63. court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre bran
64. ctor is ener CONNECTIONS FOR WIRE FEEDER AND OTHER gized closed This also means that the main power EQUIPMENT 115V AND 42V The 14 pin amphe transformer and all auxiliary control transformers are nol receptacle provides either 115 or 42 VAC as well energized as remote control connections Terminal strips with screw connections are located behind the hinged control panel for hard wired control A strain relief connector is provided for cable entry The 42 VAC auxiliary is not available at the terminal strip 8 VOLTMETER ELECTRODE OR ELEC TRODE SWITCH Selects the electrode polarity for the remote work sensing lead 421 when using 2 ON OFF POWER TOGGLE SWITCH Energizes or deengergizes the input contactor The switch turns the machine ON or OFF Position I is ON position 0 is OFF 3 OUTPUT CONTROL POTENTIOMETER Controls output voltage Return to Section TOC Return to Master TOC 4 OUTPUT CONTROL SWITCH WITH LOCAL OR automatic or semiautomatic wire feeders It must REMOTE POSITIONS Selects the mode of control agree with the actual electrode polarity chosen and In the Local position control is by the machine con with the wire feeder polarity switch on the feeder trol panel In the Remote position control is by o THERMAL PROTECTION INDICATOR LIGHT This SE EE unit or through an optional light indicates that either of the two protective ther mostats has opened Welding output is disabled but 5 DC VO
65. d cap screw 1 2 turn Tighten first cap screw 1 4 turn Stop N O QO W m Assembly now has the proper clamping force 8 Perform the Active SCR Test CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn STOP o a C Iw Assembly now has the proper clamping force 7 Perform the Active SCR Test IDEALARC CV 400 LINCOLN B F 42 F 42 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 23 HOUSING AND PRESSURE PAD FOR 5 8 WIDE LEAF SPRING STEEL PRESSURE PAD Return to Section TOC Return to Master TOC HOUSING O10 eB ES 82 PROCEDURE FOR THE FIGURE F 24 CLAMP ASSEMBLY amp E 5 8 INCH WIDE SPRING 1 Place a piece of sleeving around each cap HEX NUT S 5 screw x 2 Insert cap screws through the leaf spring The leaf spring is flat so the orientation of the leaf spring does not matter HEAT SINK 3 Place the steel pressure pad in the housing with the 1 8 inch wi
66. d capacity over NEMA rated 36V at 400 amps Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o F C o G iz SIS ol cc a Return to Section TOC Return to Master TOC Return to Master TOC A 3 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS AA WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground Turn power switch off before connecting or discon necting cables or connections Always connect grounding terminal to a proper elec trical earth ground Only qualified personnel should install use or ser vice this equipment LOCATION AND VENTILATION Place the IDEALARC CV 400 where clean cooling air can flow freely in through the front louvers and out through the rear louvers Keep dust dirt and other for eign materials that can be drawn into the machine to a minimum Failure to observe these precautions can lead to excessive operating temperatures and nuisance shut downs THE CV 400 carries an IP 21 environmental rating Locate indoors or shelter from falling water such as rain LIFTING AA WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using the lift hook if it is equipped
67. d throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in gaining access to the fan blade and fan motor for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver 3 8 Wrench Allen head type wrench IDEALARC CV 400 LINCOLN B F 34 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 35 F 35 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continued FIGURE F 18 FAN MOTOR MOUNTING DETAILS MOUNTING BRACKETS PROCEDURE 1 Remove the main input supply power to the machine Using the 5 16 nut driver remove the case top and sides The fan blade can be removed using the Allen head wrench NOTE You may need to loosen the machine case back to gain clearance to remove the fan See Figure F 18 If the fan motor is to be removed the leads to the motor must be disconnected This will require cutting the wires or breaking the splice SHROUD ATTACHED TO CASE BACK
68. d was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O amp 9 o o 2 x E O x Return to Section TOC Return to Master TOC Q O E 7 x 3 o x TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical damage is evident when the sheet metal cover s are removed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Contact your local authorized Lincoln Electric Field Service Facility for technical assistance TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 216 383 2531 or 1 800 833 9353 WELD Machine is dead no output no fan no pilot light Make sure the input power switch is ON Check the three phase input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines
69. de connected for positive polari ty To change polarity a Set the CV 400 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative output terminal c Move the work cable to the positive output ter minal d Set the VOLTMETER toggle switch to negative FIGURE C 4 LN 7 WIRE FEEDER CONNECTION TO THE IDEALARC CV 400 NA 7 WIRE FEEDER TERMINAL CONTROL V STRIPS lt TO ee Wee LINE 7 2l S al INPUT CABLE 4 PLUG GND 219 21 BLANKIS 4 31 S el 2 328 31 A 32 ae d c J mee ei 75 7 8 SL 76 r 77 Si m ML O NEGATIVE POSITIVE ELECTRODE o KOTON CS AUTOMATI WORK EQUIPMENT IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 58 n o G AIS SIS mlt 3 2 ol cc a Return to Section TOC Return to Master TOC Return to Master TOC 1 C 7 ACCESSORIES CONNECTING THE LN 8 OR LN 9 TO THE IDEALARC CV 400 Set the CV 400 POWER toggle switch to the OFF 0 position 2 Disconnect main AC input power to the CV 400 3 Connect the wire feeder control cable leads to the CV 400 terminal strip as shown in Figure C 5 Connect the wire feeder control cable ground lead to the frame terminal marked fi Extend wire feeder control
70. de standoff facing up See Figure F 23 4 Insert cap screws and leaf spring into plastic housing being sure that the steel pressure pad remains in position Pressing on the cap screw heads should produce a rocking action of the spring in its housing HEAT SINK 5 Insert the clamp assembly through the heat sinks Install nuts Tighten the clamp nuts equally on the cap screws until finger tight Be sure that the leaf spring is not cocked in the housing See Figure F 24 Heat sinks may not be exactly as pictured olo O o EE S n o G AIS o cic 3 2 ol aja HOUSING 6 Reinspect the SCR for proper seating LEAF SPRING CAP SCREW Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC Q O p E 7 x 3 o x F 43 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws
71. deJ pjeog od B5unoous lqno4 jaaa pseog wo Bunjnsea SHAE 40 AujigisuodseJ ou seuinsse ou199 3 UjooU ILON R o 1896L S tc o o et e _ i e a O z e lt lt O3 lt ki EIS BU E Ez O 5 Luo w o e LO GENERAL INFORMATION T ELECTRICAL SYMBOLS PER E1537 CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED Ke DIODES 1 AMP 400 VOLT UNLESS OTHERWISE SPECIFIED G OP AMPS LM124 UNLESS OTHERWISE SPECIFIED V COMMON CONNECTION T FILENAME 819687 3EA UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP a ON HOLES SIZES PER E 2056 x THE LINCOLN ELECTRIC CO TYPE IDEALARC DC400 Ee EE CLEVELAND OHIO U S A sugggcr 9NUBBER SCHEMATIC Q ON ALL ANGLES IS 5 OF A DEGREE NONE a MATERIAL TOLERANCE t TO AGREE SCALE JE SHT i WITH PUBLISHED STANDARDS DR MCW DATE 3 26 90 CHK SUP S D G wo S 19687 6 IH NOL Jeep 0 LUS DOL Jeep 0 LUS DOL Jeep 0 uunjeH DOL Jeep 0 UuunjeH DOL uonoes oj uumeg DOL uonoes oj uumeg DOL uonoes oj uumeg DOL uonoes oj uumeg G 8 NOTES IDEALARC CV 400 LINCOLN G 8 NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes oj uumeg
72. e PRESENT ON EUROPEAN Oo amp OPTIONAL SS o t ole 12 9 94F L9269 olo w r SIE Be Zi l GK ajo IDEALARC CV 400 LINCOLN ELECTRIC Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 Fle S5 o Hie EK 2 2 ol cc a Return to Section TOC Return to Master TOC Return to Master TOC G 3 ELECTRICAL DIAGRAMS Wiring Diagram Code 10087 G 3 230 460 575V H SHOWN CONNECTED FOR 230 V NBi H4 TO SUPPLY y LINES H2 ndm RECONNECT PANEL Fyn qu D 3 TO GROUND PER NATIONAL 15 N B ELECTRICAL CODE FAN MOTOR TO PRIMARY Tt MA COILS 31 CONNECT OR MR oe 32A nuaa Ge 2 4 AUXILIARY 7 CIRCUIT 42 SE SHOWN ON 115V i COILS 10 BREAKER L INPUT H3 i 12 42A 1 0 241 0 10 Sender CONNECTION Ha 5 X2 E 42V SECONDARY PRIMARY DIAGRAM 231 i i THERMOSTAT 41 THERMOSTAT T2 CONTROL i To 99 3 5 41 TRANSFORMER i 201 i TOP 28 i 231 PRIMARY 18 21V 21 15 NN w 1 akaona usa ss i S 204 i i CAPACITOR i Aes E S DISCHARGE i BOTTOM 4 5 6 CAPACITOR i i PRIMARY ZIEL EN bs SEC DISCHARGE o H ov i ie 2 o 30 OPTION j R U x s i ra s i i N A PN 16 17 18 i 10A l 0 5 f 0W i EI SLOW i BLOW pm id E E E os f 0W i E
73. eath Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Mar 95 IDEALARC CV 400 LINCOLN B Return to Master TOC Return to Master TOC o Hr E 7 E x E o x Return to Master TOC SAFETY SE WELDING SPARKS can gt 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 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 Do not heat cut or weld tanks drums or containers until the proper s
74. er TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 46 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main transformer for mainte nance or replacement MATERIALS NEEDED 5 16 Nut driver 9 16 Socket wrench 9 16 Box end wrench 1 2 Socket wrench 1 2 Box end wrench 3 8 Nut driver or socket wrench 9 16 Deep well socket wrench IDEALARC CV 400 LINCOLN B F 46 Return to Section TOC Return to Master TOC Return to Section TOC O1
75. er TOC Return to Master TOC o O Hr E 7 E x E o x Return to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machi
76. eturn to Section TOC Return to Master TOC Return to Section TOC O10 O10 E It S5 min Hie iz SIS O O cc a Return to Section TOC Return to Master TOC Return to Master TOC C 5 ACCESSORIES 5 Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larg er insulated wire Tape the bolted connection with insulating tape b An S 16586 X remote voltage sensing work lead is available for this purpose c Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 421 lead to the work cable for ease of use 6 Connect NA 5 wire feeder control jumpers on Voltage Control Board See the NA 5 operator s manual NOTE For proper NA 5 operation the electrode cables must be secured under the clamp bar on the left side of the NA 5 Control Box NOTE The connection diagram shown in Figure C 3 shows the electrode connected for positive polarity To change polarity a Set the CV 400 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative output terminal c Move the work cable to the positive output termi nal d Set the VOLTMETER toggle switch to negative e See NA 5 manual for changing welding polarity IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o
77. g temperatures may be caused by insufficient cooling air or by operating the machine beyond the duty cycle and output rating The primary thermostat is located on the nose of the center bottom primary coil The secondary thermostat is attached to the lead connecting the secondaries Both thermostats are connected in series with the trigger circuits If the machine is over heated the thermostats will open and output will be zero The thermal protection light will glow and the fan will continue to run See Figure E 4 CV 400 Trigger And Thermal Light Circuit Under nor mal conditions the Thermal Light is shorted out by the circuit breaker and thermostat circuit If the ther mostats or the circuit breaker opens more current will flow through the Thermal Light circuit and the light will glow The power source is also protected against overloads on the SCR bridge assembly through the solid state fault protection circuit This circuit senses an overload on the power source and limits the output to approxi mately 550 amps by phasing back the SCRs Protection is also provided to protect the circuitry from accidental grounds If the customer accidentally grounds 75 76 or 77 to the positive output lead the CV 400 output will be reduced to a very low value thus preventing any damage to the machine If the ground occurs between 75 76 and 77 and the negative output lead one of the PC board electronic self restoring fuses will blow preven
78. gle Switch Output Control Potentiometer Output Control Switch with Local or Remote posi tions Auxiliary Power Connections for Wire Feeder and Other Equipment 115V and 42V Thermal Protection Indicator Light e Voltmeter Electrode or Electrode Switch DESIGN FEATURES Input line voltage compensation keeps output con stant for fluctuations of 10 SCR control Hinged front control panel provides easy access to printed circuit boards and other control circuitry Fully enclosed fan motor with permanently lubricated sealed ball bearings needs no maintenance Fully recessed control panel protects controls and minimizes accidental contact Recessed output terminals reduce chance of acci dental contact Low profile case permits installation under a work bench Removable rear access panel provides easy access to input contactor and input lead connections Removable case sides provide easy access for ser vice or inspection even when machines are stacked Double dipped transformer SCR bridge and choke resist corrosion IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC O10 O10 Fle S5 o Hie EK gje ol cc a Return to Section TOC Return to Master TOC Return to Master TOC OPERATION WELDING CAPABILITY LIMITATIONS The CV 400 has the following duty cycle ratings If the The IDEALARC CV 400 has no pro
79. hooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine O10 O o E It S8 mio o G EK els ol 0 xix IDEALARC CV 400 LINCOLN ELECTRIC euigoeui y 0 eDeurep ul jnsoJ pjnoo Spa pieoq Od dodu ueroiuuoe 10 JO EIBdO UYL eui 0 JeBuep ul jnsaJ Aew pue ufisep eui jo Ayjenb eui esiuoud w09 eUJ 1I eouis jrede pue BuroousejgnoJ je e preoq seDeunoosip 211198 3 ujoour juo e2uoJ6jJaJ 10 p piA01d s uoneuuolul SIU 9H199 3 U OOUT WO SI0EIEAG 1ou 91e SjuSuoduio peog UI pejuug jenpiaipuj AUS UM 10 9eJ ANOA ejepijeAui IM Suredas pjeog od B5unoous lqno4 jaaa pseog wo Bunjnsea senipiger 40 AujigisuodseJ ou seuinsse ou199 3 UjooU ILON
80. ile the switch tive capacitor lead and small lead terminal E POS and aner Wie Switch Ie ERR 23 Reconnect lead 204 to resistor R2 the SCR is functioning b If the voltage is 3 6 volts only when the Switch is closed or if there is no voltage when the switch is closed the SCR is defective Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN F 28 F 28 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC CH1 0 volts Return to Section TOC Return to Master TOC 20 volts 2ms This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 20 volts and that each horizontal divi sion represents 2 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal O10 O10 Fle S5 o Hie iz SIS ol cc a SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 2 ms Div Coupling DC Trigger es Internal Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 29 F 29 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED CH1 Return to Section TOC
81. input voltage is being applied to the machine If remote control is being used set the Output Control switch S2 to the Machine or Local position and control the weld output with the machine Output Control R4 If the problem is solved check the remote control unit or wire feeder and associat ed control cable RECOMMENDED COURSE OF ACTION 1 Check the Output Control R4 Normal resistance is 10 000 ohms Also check associated wiring for loose or faulty connec tions See the Wiring Diagram Check the Output Control switch S2 and associated wiring See the Wiring Diagram 3 Perform the 4 Perform the SCR Diode Bridge Rectifier Test 5 The control board may be faulty Replace The machine will not shut off when the power switch is put in the OFF position Make sure the three phase input lines are connected correctly to the CV 400 Check the input power switch S1 and associated leads See the Wiring Diagram 2 Perform the Input Contactor CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O amp 9 o o o 2 KH
82. lacement of the SCR diode assembly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 7 16 Wrench 1 2 Wrench 9 16 Wrench 3 8 Wrench Slot head screw driver 1 2 Socket and extension Ojo O o Fle S n o G iz DE mlt 3 2 ol cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 37 CHOKE LEAD CONNECTION F 37 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT continued FIGURE F 19 SCR DIODE ASSEMBLY DETAILS GLASTIC STIFFENERS POSITIVE CAPACITOR LEAD SECONDARY LEADS MOUNTING BRACKETS SCR DIODE ASSEMBLY MOUNTING FASTENERS PROCEDURE 1 10 11 Remove the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Remove the glastic stiffeners one on right side two on left side See Figure F 19 Remove lead 220 from the right side of the negative heat sink plate Remove the positive capacitor lead and shunt from the positive heat sink plate See Figure F 19 Remove the choke and negative capacitor leads from the left side of the negative he
83. light is on but the machine has no welding output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 If the amber thermal protection light is on the primary or sec ondary thermostat is open Allow machine to cool Make certain the output trigger circuit 2 and 4 is being acti vated by a closure Check the 10 amp circuit break er in the 42VAC circuit Reset if necessary If remote control is not being used make certain the Output Control switch S2 is in the Machine or Local position Check for loose or faulty welding cable connections RECOMMENDED COURSE OF ACTION 1 Perform the Main Transformer 2 Perform the SCR Diode Recti fier Bridge Test 3 The control board may be faulty Replace The input contactor CR1 chatters Make certain the three phase input voltage matches the machine rating plate and the reconnect panel 1 Perform the Input Contactor CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O amp 9 o o o 2
84. n subsequent damage of the SCR Handle all SCRs with care PROCEDURE 1 Remove the main input supply power to the machine 2 Perform the SCR Diode _ Rectifier Assembly Removal and Replacement pro cedure 3 Alternately loosen nuts 1 2 turn each until heat sinks are loose Remove nuts and leaf spring IT IS RECOMMENDED THAT NEW HARDWARE LEAF SPRING AND HOUSING BE USED FOR REASSEMBLY 4 Remove the old SCR Clean the area on the heat sink around the SCR mounting surface using a putty knife or similar tool DO NOT SCRATCH THE SCR MOUNTING SURFACE Polish each heat sink s mounting surface using NO 000 fine steel wool Wipe surface clean with a lint free cloth or paper towel Inspect the mounting surfaces of each new SCR a Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the SCR mounting surfaces Apply a thin 0 001 to 0 003 layer of PEN ETROX A 13 Lincoln Electric E2529 or PENETROX A heat sink compound to each heat sink s SCR mounting surface a Care must be used to prevent foreign material contamination of the SCR to heat sink junction Place the new SCR between the heat sinks Be sure that the outer metal ring of the SCR is facing toward the same heat sink as the old SCR s metal ring Be sure that the roll pin of the heat sink engages the hole in the SCR The SCR contact surfaces must sit flat against both heat sink surfaces Return to Section TOC Retu
85. nal 3 Set the OUTPUT CONTROL switch to Local Exception when using an LN 9 LN 9 GMA or NA 5 wire feeder set the switch to Remote Otherwise the wire feeder may automatically shut down 4 Set the ON OFF switch to the ON position I The power source pilot light glows and the fan starts 5 Set the OUTPUT CONTROL Potentiometer to the desired voltage 6 Make the weld REMOTE CONTROL The toggle switch on the control panel labeled Output Control Remote gives you the option of controlling the machine output from a remote location In the Remote position a wire feeder with remote control capabilities or a remote control device such as a K775 must be connected to the CV 400 See the Accessories section for wire feeder installation infor mation IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Ojo O o Fle S n o G iz D mlt 3 2 ol cc a Return to Section TOC Return to Master TOC Return to Master TOC B 7 OPERATION OVERLOAD PROTECTION The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling One thermostat is located on the nose of the center bottom primary coil and a second thermostat is attached to the lead connecting the secondaries Both thermostats are connected in series with 2 4 circuit If the machine is overloaded the primary thermostat will open the outp
86. nd 32 on the terminal strip Also test for 42VAC between pin K lead 42 and pin lead 41 in the 14 pin amphenol See Figure F 7 a Remove the sheet metal screws from the control box cover with the 5 16 nut driver and flip the cover down It does not have to be completely removed to perform the tests b If the above voltage checks are incor rect check for loose or faulty wiring Check continuity c f the wiring is good then the main transformer may be faulty Replace the main transformer Expected VAC 18 IDEALARC CV 400 LINCOLN B 14 PIN AMPHENOL Test with an AC voltmeter for 21VAC for each phase angle winding at plug P1 on the control board as shown in Figure F 8 and the accompanying table NOTE If the main input supply voltage varies the main transformer voltages will vary proportionately a f the voltage is low remove plug P1 and recheck the voltage for 21VAC If the reading is normal the control board may be faulty Replace the control board b If one or more of the voltage tests are incorrect check for loose or faulty wiring c f the wiring is good then the main transformer may be faulty Replace the main transformer F 20 F 20 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 8 CONTROL BOARD PLUG P1 LOCATION Return to Section TOC Return to Master TOC G2629 CV 400 CV 500 CONTROL 203
87. nd 204 to resistor R2 5 Connect the negative capacitor strap to the nega tive rectifier plate Connect the positive capacitor strap to the output shunt and positive rectifier plate 7 Attach the fiber baffle on the bottom choke lead 8 Attach the two fiber baffles to the left and right sides of the lift bail adjacent to the main trans former Install the machine case top and sides NOTE When aluminum leads are reconnected apply a thin layer of Dow Corning 340 Heat Sink Compound Lincoln E1868 to the mating surfaces IDEALARC CV 400 LINCOLN B F 53 F 53 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine e f it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 208 3 60 220 3 60 230 3 60 380 3 60 400 3 60 415 3 60 440 3 60 460 3 60 500 3 60 575 3 60 wesch sech sech sech sch sech lA l ll NDNnNDNPNININNDNNN Return to Section TOC Return to Master TOC 200 3 50 220 3 50 230 3 50 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 wesch sech sech sech sech lk N S Io S o S N io OPEN CIRCUIT VOLTAGES Test Points Input Hertz Open Ci
88. nd the remainder of the time in the OFF state The amount of time spent in the ON state is con trolled by the gate An SCR is fired by a short burst current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junction between gate and cathode the voltage between these terminals must be slightly greater than 0 6V Once the SCR has fired it is not necessary to continue the flow of gate current As long as current continues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC CV 400 LINCOLN B E 6 NOTES IDEALARC CV 400 LINCOLN E 6 NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes oj uumeg Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING amp REPAIR SECTION S g Troubleshooting amp Repair Gecthon I Section F 2 How to Use Troubleshooting Guide aaaaaaaaaaaaaassaaassaasanaasaaaanaaaanannnaannn
89. ne souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un
90. ng 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z8
91. nnnnanansnananaanaaaanaaaa F 2 PC Board Troubleshooting Procedures aauaaaaaaaasaaasaaassanassaasanaasaaaasnanasnannsannsannnanannannna F 3 2 Troubleshooting GUuId _ uu aaa au asnaanan qay RACE Na eb OK reca F 4 F 9 Test uec eee F 10 Control Transformer T2 Voltage Test F 10 Input Contactor GSt uiii i eint ete aei ae Dod pu rd d ae da eR da lace pud eher F 13 Main Transformer T1 Voltage Test L nenne F 16 Static SCR Diode Rectifier Bridge Test F 21 Active SCR lest m E F 24 Oscilloscope WAavelforiTis oer ttti rar tei e ete E da arx da Eee a E ex ua edad F 28 B Normal Open Circuit Voltage Waveform I F 28 Typical Output Voltage Waveform Machine Loaded sees F 29 S Typical SCR Gate Voltage Waveform tnnt F 30 3 Abnormal Output Voltage Waveform Machine Loaded sss F 31 z Q Replacement Procedure enne nennen nennen u u F 32 E Input Contactor CR1 Cleaning Heplacement a F 32 E Fan Motor and Blade Removal and Replacement esee F 34 SCR Diode Rectifier Assembly Removal and Replacement sasaran F 36 Mounting of Stud Type Diodes to Aluminum Heat Gimks F 44 Main Transformer Removal and Replacement sse F 46 e UE F 53 o O E E 7 c x E o x Return to Master TOC IDEALARC CV 400 LINCOLN
92. nnnsannsanannanansnanannananaannanansananaaanina B 3 Miel ET B 3 Welding Capability eet Mine pei ente eiae Rot ere indice B 4 Blog zuo DE B 4 Controls and Settings EE B 5 Welding ele EE B 6 Local COMMON RE B 6 Remote Control a Ee a ERE ee EROR aqa PARARE TE ROS B 6 Overload Protection uuu uuu m B 7 Auxillary nior ERR B 7 Return to Master TOC o O E E 7 c x E o x Return to Master TOC IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 9 o o o 2 KH 5 O x Return to Section TOC Return to Master TOC o O E 7 x 3 o x B 2 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be 3 dangerous 40 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone 7 WELDING SPARKS can cause fire or explosion Keep flammable material away e Do not weld on containers that have held com bustibles ARC RAYS can burn Wear eye ear and body protection
93. nput contactor CR1 and reconnect panel assembly for multiple voltage connec tion Input power is connected to the three line termi nals on the input contactor See IDEALARC CV 400 LINCOLN B INSTALLATION o e S FIGURE A 1 e RATING PLATE LOCATION ol oO lk 9 d LE O 2 2 o EE 9 o Oo SE E L Oo SUI UII GFR Ne o CV 400 o Q o S 3 2 eg S V 2 E O O 9 2 EO EOS o o E E o o o o 2 2 dc 1 RATING PLATE GROUND CONNECTION INPUT SUPPLY CONNECTIONS The frame of the welder must be grounded An earth Be sure the voltage phase and frequency of the input olo grounding lead must be connected to the grounding power is the same as specified on the rating plate e terminal marked on the input box floor with the symbol 5 5 rh See Figure A 2 Refer to Technical Specifi A WARNING B E ZE for proper ground wire size ELECTRIC SHOCK can kill N N CAE o Have a qualified electrician cle install and service this equip z ment x x Turn the input power off at the fuse box before working on this equipment Do not touch electrically hot parts Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Retu
94. nsing work lead is available for this purpose c Keep the 21 lead electrically separate from the work cable circuit and connection d Tape the 21 lead to the work cable for ease of use NOTE The connection diagram shown in Figure C 2 shows the electrode connected for positive polarity To change polarity a Set the CV 400 POWER toggle switch to the OFF 0 position b Move the electrode cable to the negative output terminal c Move the work cable to the positive 4 output ter minal d Set the VOLTMETER toggle switch to negative CONNECTING THE NA 5 TO THE IDEALARC CV 400 1 Set the CV 400 POWER toggle switch to the OFF 0 position 2 Disconnect main AC input power to the CV 400 3 Connect the wire feeder control cable leads to the CV 400 terminal strip as shown in Figure C 3 4 Connect the wire feeder control cable ground lead to the frame terminal marked 777 NOTE The CV 400 must be properly grounded FIGURE C 3 NA 5 WIRE FEEDER CONNECTION TO THE CV 400 Mine TERMINAL CONTROL 7s STRIPS lt TO o p BOX 4 o GND ale 21 BLANK S S 4 aile S 2 32 8 31 76 S_S 75 7715 76 E 77 Q Si r L O NEGATIVE POSITIVE ELECTRODE L TO CABLE TO WORK AUTOMATIC EQUIPMENT IDEALARC CV 400 LINCOLN B R
95. o Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 E x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 32 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in inspecting cleaning and replacing the input contactor MATERIALS NEEDED Phillips head screwdriver 5 16 Socket wrench Flat head screw driver 7 16 Socket wrench Low pressure air source IDEALARC CV 400 LINCOLN B F 32 Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle 58 n o G AIS SIS mlt 3 2
96. o O O ov n 2 2 Ge 2 CIE K TE sx o c E d 98 oO o EA m A J e aa LF des O e L SNUBBER i Q IE M15370 3 i O Oo n ete 4 S 1 S olg EK els E IE 5 5 3 o ITEM DEOD PART NO DESCRIPTION g C1 C2 C3 3 T11577 68 68 400 C4 C5 2 111577 46 05 600 R1 R2 R3 3 112733 10 10 2W TP1 TP2 TP3 3 113640 12 38J TP4 TP5 2 113640 18 160J TP6 1 T13640 16 80J NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components are not available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B geri euigoeui eui 0 eDeurep ul jnsoeJ p no2 Spa pueog Od dodu ueroiuuoe 10 101ejed eutuoe y eui oj JeDuep ul jnsaJ Few pue uBis p eui jo Ayjenb eui esiuoud w09 eUJ 1I eouis JredeJ pue BuroousejgnoJ je e preoq seDeunoosip 9114907 ujoour juo e2uoeJ6jaJ 10 p piA01d s uoneudolul siu 3H198 3 UJO9UT WO SI0EIEAG JOU o1e SjuSuoduio peog UDO paul jenpiaipuj Augue 10 oeJ ANOA erjepijeAui IM sare
97. obe of diode D1 The resistance should be high See Figure E11 b If a low resistance is measured in both meter polarities diode D1 is shorted Replace diode D1 c If a high resistance is measured in both meter polarities diode D1 is open Replace diode D1 12 Test diodes D2 D3 and D4 for proper oper ation using the same procedure described in Step 11 13 Reconnect all leads and molex plugs 14 If this test did not identify the problem or to further test the SCRs go to the Active F 24 F 24 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST AA WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou E O bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD P S SE AE j DESCRIPTION E This test will help determine if the device can be gated ON and conduct current from anode 51 3 SIS to cathode ojo MATERIALS NEED
98. on The following descriptions show how to connect the wire feeders using the terminal strip AUTOMATIC WIRE FEEDERS CONNECTING THE NA 3 TO THE IDEALARC CV 400 1 Set the CV 400 POWER toggle switch to the OFF 0 position 2 Disconnect main AC input power to the CV 400 3 Connect the wire feeder control cable leads to the CV 400 terminal strip as shown in Figure C 2 4 Connect the wire feeder control cable ground lead to the frame terminal marked 777 NOTE The CV 400 must be properly grounded FIGURE C 2 NA 3 WIRE FEEDER CONNECTION TO THE IDEALARC CV 400 Maur TERMINAL CONTROL STRIPS CABLE d lt lt TO AUTOMATIC CONTROL BOX NEGATIVE POSITIVE ELECTRODE CABLE TO AUTOMATIC WORK EQUIPMENT IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o o 8 E x 3 2 x Return to Section TOC Return to Master TOC Q O Hr E 7 x 3 o x CA ACCESSORIES 5 Extend wire feeder control cable lead 21 so it can be connected directly to the work piece a Make a bolted connection using AWG 14 or larg er insulated wire Tape the bolted connection with insulating tape b An S 16586 X remote voltage se
99. on TOC Return to Master TOC o O 2 o 8 E x E 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x C 3 C 3 ACCESSORIES CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS A WARNING ELECTRIC SHOCK can kill e Only qualified personnel should per form this maintenance Turn the input power OFF at the dis connect switch or fuse box before working on this equipment Do not touch electrically hot parts Insulate yourself from work and ground Always wear dry insulating gloves Auxiliary power for wire feeder operation is available at both a 14 pin amphenol and at terminal strips with screw type connections located behind the hinged con trol panel on the front of the machine The 14 pin amphenol can provide both 115 VAC pins A and J and 42 VAC pins and K The terminal strip provides only 115 VAC terminals 31 and 32 The two circuits are iso lated and each is protected by a 10A circuit breaker NOTE When using a CV 400 with wire feeders there may be a small spark if the electrode contacts the work or ground within a few seconds after releasing the trig ger With some wire feeders when the electrical inter lock is in the ON position the arc can restart if the elec trode touches the work or ground during these few sec onds Refer to K828 1 capacitor discharge circuit ear lier in this secti
100. ormer and choke assembly is now loose and free to slide or tip on the base of the machine 10 Remove the lift bail by lifting straight up and clear from the machine IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 O10 Fle S5 o Hie iz SIS ol cc a Return to Section TOC Return to Master TOC F 48 F 48 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 26 CHOKE REMOVAL REMOVAL OF CHOKE AND TOP IRON ASSEMBLY 1 Remove the three two left and one right glastic stiffeners connecting the negative rec tifier plate and choke assembly to the main transformer thru bolts See Figure F 26 Remove the top choke lead from the negative rectifier plate Remove the bottom choke lead from the neg ative output terminal Using the 9 16 deep well socket wrench remove the four thru bolts that clamp the top E iron and choke assembly to the bottom E iron NOTE for easier reassembly clean the threads THRU BOLTS 4 BOTTOM E IRON 5 Using a hoist carefully lift the choke and top iron assembly out and clear of the trans former coils NOTE The coils may be stuck to the top iron and may require some careful prying to dislodge them Depending upon which coils are to be replaced it may be advantageous to remove some of the s
101. r control Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o E it C els ois ele ES bi cc a Return to Section TOC Return to Master TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER OUTPUT CONTROL CONTROL TRANSFORMER MAIN TRANSFORMER Wu Vy UV daomzzoomz INPUT CONTACTOR REMOTE CONTROL CONTROL BOARD 14 PIN AMPHENOL INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER The desired three phase input power is connected to the CV 400 through an input contactor located in the input box at the rear of the machine Two phases of the input line are also connected to the control transformer which through the power switch supplies power to activate the input contactor A reconnect panel allows the user to configure the machine for the desired input voltage This AC voltage is applied to the primary of the main transformer The transformer changes the high voltage low current input power to a lower voltage higher current output O CONTROL BOARD NEGATIVE OUTPUT TERMINAL zOoP uommT AOP ugommmTn OUTPUT CAPACITORS POSITIVE OUTPUT TERMINAL SCR DIODE ZP HYBRID BRIDGE The finishes or neutrals of the main secondary coils are connected together and the three starts of the
102. r right Do not put your hands near the engine fan Do not attempt to side the work cable should also be on your right side override the governor or idler by pushing on the throttle con trol rods while the engine is running 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance 2 d 5 Do not work next to welding power source work disconnect the spark plug wires distributor cap or magneto wire as appropriate Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Master TOC Return to Master TOC o O E E 7 c x E o x Return to Master TOC SAFETY 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 hands 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 gratings or scaffolds when in cramped positions such as sitti
103. rcuit Volts Welding Output Terminals 60 43 47VDC Welding Ouput Terminals 50 43 47VDC olo O o Fle 58 n o iz g 2 mt 3 2 ol cc a Auxiliary Output 31 32 60 114 124VAC Auxiliary Output 31 32 50 109 119VAC Auxiliary Output 41 42 60 43 8 47 5VAC Auxiliary Output 41 42 50 42 0 45 6VAC Auxiliary Output 51 52 50 220 231VAC WELDING OUTPUT LOAD TEST Output Control Setting Amps Volts Minimum 75 to 150 6 to 11 Maximum 525 more than 41 2 Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 54 NOTES IDEALARC CV 400 LINCOLN amp F 54 NOL Jeep 0 LUS NOL Jeep 0 LUS DOL Jeep 01 uunjeH DOL Jeep 01 uunjeH DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes 0 uumeg DOL uonoes oj uumeg Return to Master TOC Return to Master TOC o E E 7 c x E o x Return to Master TOC i ELECTRICAL DIAGRAMS Electrical Diagrams Section U n n Section G Wiring Diagram Codes 10084 10085 10086 nennen nennen nnns G 2 Wiring Diagram Code 10087 G 3 Control PC Board G2629 1 Layout G 4 Control PC Board G2629 1 Schematic sess nnne enne G 5 snubber PC Board M159370 3 LayOUt rt iet et dep ten ha HERE ee Reb NEEN aea G 6 Snubber PC Board M15370 3 Schematic U enne nnns G 7 IDEALARC CV 400 LINCOLN B G 1 G 2
104. resents 5 milliseconds in time Note Scope probes connected at SCR gate and cathode probe to gate probe to cathode SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal IDEALARC CV 400 LINCOLN F 31 F 31 TROUBLESHOOTING amp REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING Return to Section TOC Return to Master TOC CH1 HHH REEL EE EEE E HA E 0 volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is NOT the typical DC output voltage waveform One output SCR is not functioning Note the ripple in the waveform One SCR gate is disconnected to simulate an open or non functioning output SCR Each vertical division represents 20 volts and each horizontal division repre sents 5 milliseconds in time The machine was loaded with a resis tance grid bank The CV 400 meters read 400 amps at 36 VDC Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal O10 O10 Fle S5 o Hie EK SIS ol cc a SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Trigger esee Internal Return to Section TOC Return t
105. rformed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in mounting stud type diodes to the aluminum heat sinks on the DC 400 Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 1 2 Open end wrench Lincoln E1868 Dow Corning 340 Heat Sink Compound Slip type torque wrench No 000 fine steel wool Ojo O o Fle S n o G iz DE mlt 3 2 ol cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 45 F 45 TROUBLESHOOTING amp REPAIR O10 P MOUNTING OF STUD TYPE DIODES s TO ALUMINUM HEAT SINKS continued olg PROCEDURE 1 Remove the main input supply power to the DIODE STUD FOOT INCH ke 2 With the 5 16 nut driver remove the case 3 4 16 25 27 300 324 top and sides SEN 102 5 3 Loosen the appropriate diode nut
106. rminals with E2547 terminal boots FIGURE F 31 SECONDARY LEAD TRIM AND WELD DETAIL Ojo O o Fle 58 n o G iz 2 2 mlt 3 2 cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC o O E 7 x 3 o x F 52 F 52 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE 1 NOTE The following procedure assumes you have completely reassembled the transformer coils as described in the procedure above The lower iron has remained in place in the 9 machine See Figures F 25 and F 26 1 Attach the bottom choke lead to the negative out put terminal 3 2 Attach the top choke lead to the negative rectifier plate 4 REASSEMBLE THE LIFT BAIL Carefully position the lift bail onto the machine base Using the 9 16 socket wrench attach the lift bail to the base of the machine with four bolts flat washers and lock washers Using the 9 16 socket wrench attach the lift bail to the transformer top and bottom irons with four bolts Attach the sheet metal screw that holds the capac itor bank assembly to the case back Connect leads 220 a
107. rn to Master TOC IDEALARC CV 400 LINCOLN B F 40 F 40 TROUBLESHOOTING amp REPAIR Q o SCR REMOVAL AND REPLACEMENT continued K _ 5 FIGURE F 21 1 2 WIDE LEAF SPRING FIGURE F 22 CLAMP ASSEMBLY 2 gt 2 2 ele HEX NUT ala B qum TT 9 SPRING CURVATURE 1 2 lt EXAGGERATED Qmm CT HEAT SINK SCR 10 Go to the procedure below that matches your machine s cap screws NOTE WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PROCEEDING TO THE ASSEMBLY PROCEDURE Two different designs of leaf springs and housings have been used to clamp the SCR to the rectifier The two different designs can be identified by the size of the leaf spring One design uses a 1 2 inch wide leaf spring and the other uses a 5 8 inch wide spring The different designs require different assembly and clamping procedures The assem bly procedure will be different depending upon the thread on the cap screws A 1 4 28 thread requires a different tightening procedure than a 1 4 20 thread PROCEDURE FOR THE 1 2 INCH WIDE SPRING 1 Place a piece of sleeving around each cap screw HEAT SINK Return to Section TOC Return to Master TOC HOUSING LEAF SPRING CAP SCREW 2 Insert cap screws through the leaf spring Orient the leaf spring so that its ends are curved upward toward the cap screw heads See Figure F 21 Pressing on the cap screw heads should produce a rocking motion of the spring in it
108. rn to Master TOC Q O E 7 x 3 o x F 9 F 9 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Poor arc characteristics Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Make sure the correct weld pro cedures are being used Electrode Gas etc Check the welding cables for loose or faulty connections RECOMMENDED COURSE OF ACTION 1 Check the output capacitors and connections A capacitor failure is indicated if the small vent plug on top of a capacitor is raised or blown out WARNING The liquid elec trolyte in these capacitors is toxic Avoid contact with any portion of your body Clean up vented electrolyte using rubber gloves and a water dampened cloth Any elec trolyte which gets on skin clean with soap and water The control board may be faulty Poor arc striking with semiautomat ic or automatic wire feeders Make sure the correct weld pro cedures are being used Electrode Gas etc Check the welding cables for loose or faulty connections The control board may be faulty The welding arc is variable and sluggish Check the input voltage at the CV 400 making sure the correct voltage and all three phases are being applied to the machine Make sure the welding process is correct for the machine set tings
109. rn to Master TOC Return to Section TOC Return to Master TOC O10 O10 Fle s s Ri Hie EK SIS ol cc a Return to Section TOC Return to Master TOC A 5 A 5 INSTALLATION FIGURE A2 REAR PANEL INPUT SUPPLY LINE ENTRY HOLE INPUT CONTACTOR CR1 RECONNECT PANEL JUMPER LINKS GROUND TERMINAL RONDA Have a qualified electrician connect the input power leads to the L1 L2 and L3 terminals of the input con tactor Follow all national and local electrical codes Use a three phase line Install the reconnect panel jumper links see Figure A 3 for the proper input volt age See the connection diagram located on the inside cover of the access panel cover Also refer to Reconnect Procedure later in this section INPUT WIRE AND FUSE SIZE Fuse the input circuit with the super lag fuse recom mended in the Technical Specifications at the begin ning of this section or use delay type circuit breakers Choose an input and grounding wire size according to local or national codes also see the Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if you are not weld ing at high output currents Also called inverse time or thermal magnetic circuit breakers These circuit breakers trip faster as the magnetude of the fault cur rent increases FIGURE A 3 INPUT POWER SUPPLY CONNECTIONS E
110. rol board compares the commands of the output control or remote control with the feed back information and sends the appropriate gate firing signals to the SCR diode bridge See SCR Operation in this section NEGATIVE OUTPUT TERMINAL AOP uomrmimn zOoPUOmmT OUTPUT CAPACITORS POSITIVE OUTPUT TERMINAL A dry closure of leads 2 and 4 either at the termi nal strip or the 14 pin amphenol signals the control board to apply gate firing signals to the SCR diode bridge which creates a DC voltage at the output of the bridge assembly This output is filtered by the capacitors to reduce the ripple content of the wave form Thus a smoother DC output is created The choke which is in series with the negative output ter minal stores energy and provides current filtering NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC CV 400 LINCOLN B E 4 E 4 THEORY OF OPERATION FIGURE E 4 CV 400 TRIGGER AND THERMAL LIGHT CIRCUIT Return to Section TOC Return to Master TOC Return to Section TOC olo O o Fle S n o a iz D mlt 3 2 ol oO cc a Return to Master TOC THERMAL LIGHT O SECONDARY THERMOSTAT O O CIRCUIT BREAKER TERMINAL STRIP O PRIMARY THERMOSTAT CONTROL BOARD PROTECTIVE DEVICES AND CIRCUITS Two thermostats protect the CV 400 from excessive operating temperatures and overload conditions Excess operatin
111. roper main olz 4 Inspect the input contactor reconnect input supply voltage to the line side of the 2 2 panel and primary leads to the main trans input contactor CR1 See the Wiring c E former for loose or faulty connections See Diagram 5 E S Figures ES a L1 to L2 jam a Confirm that the reconnect panel is b L2 to L3 connected properly for the three phase main input power supplied to the c L1 to L3 machine See the reconnect panel connection diagram located on the inside of the input box assembly access door Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 18 F 18 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 6 MAIN SECONDARY LEAD TEST POINTS Return to Section TOC Return to Master TOC O 519 ed Us MAIN s TRANSFORMER iz SECONDARY EE LEADS EIE ala ec 8 Read the meter 11 Test with an AC voltmeter for approximate ly 42VAC across each of the three main secondary start leads located at the SCR Diode Rectifier Bridge Remove the a If proper voltage is present for all three phases proper main input supply volt O I e age iS pemg Supplied red insulating paint to achieve good con F b If proper voltage is not present in any tact if necessary See Figure F 6 See the E 2 or all of the three phases check input Wiring Diagram olg AE Mises and laada a If one or more of the above voltage AE
112. s housing If the spring does NOT rock it is installed upside down Remove the spring and turn it over Check for rocking motion See Figure F 21 O10 O10 Fle EIE o Hie iz SIS ol cc a 3 Insert cap screws and leaf spring into the plastic housing 4 Insert clamp assembly through heat sinks Install nuts Tighten clamp nuts equally on cap screws until finger tight See Figure F 22 Heat sinks may not be exactly as pictured 5 Reinspect the SCR for proper seating Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o 8 x 3 2 x Return to Section TOC Return to Master TOC Q O Hr E 7 x 3 o x F 41 F 41 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten secon
113. s or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SCRs from the output rectifier heat sink for maintenance or replacement MATERIALS NEEDED NO 000 Fine Steel Wool Penetrox A 13 Lincoln E2529 or Penetrox A 7 16 Open end wrench Allen head type wrenches IDEALARC CV 400 LINCOLN B F 38 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o o 8 x 3 2 x o O E 7 x 3 o x F 39 F 39 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 20 SCR DETAILS GATE ANODE CATHODE OUTER METAL SPECIAL INSTRUCTIONS NOTE Before disassembling the existing recti fier note toward which heat sink the outer metal ring of the power SCR is mounted Also note the positioning of the gate lead of the SCR Failure to reinstall the new SCR in the same ori entation as the original may result in subsequent damage to the new SCR and other components of the welder See Figure F 20 ACAUTION The unclamping and clamping procedure out lined below is critical for the prevention of inter nal SCR damage Failure to follow this proce dure may result i
114. stance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This procedure will determine if the correct voltage is being applied to the primary of the control transformer and induced on the secondary winding of the control transformer MATERIALS NEEDED Volt ohmmeter Multimeter 5 16 Nut driver IDEALARC CV 400 wiring diagrams See the Electrical Diagrams section of this manual IDEALARC CV 400 LINCOLN F 10 F 11 F 11 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued FIGURE F 1 CONTROL TRANSFORMER AND LEAD LOCATIONS Return to Section TOC Return to Master TOC LEAD X1 CONNECTION INPUT CONTACTOR o O 2 o 8 x E 2 x Return to Master TOC CONTROL TRANSFORMER T2 LEAD X2 CONNECTION SPLICED TO LEAD 231 TEST PROCEDURE 5 Locate control transformer leads X1 top S M and X2 o 1 Disconnect the main input supply power to F the machine a Lead X1 is connected to the input con E 2 M tactor CR1 coil located on the input side O 2 With the 5 16 nut driver remove the top of the contactor See Figure F 1 n case sides and rear input panel o b Lead X2 is spliced into lead 231 See cle 3 Locate the control transformer T2 on the the Wiring Diagram Lead 231 is con 3 3 left side of the input box facing the back of nected to the power switch S1 See Qu
115. teps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c za CYLINDER may explode b if damaged a 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
116. the machine See Figure EI Figure F 2 4 Locate the control transformer primary leads H1 H2 H3 etc See the Wiring Diagram NOTE Unused leads should be taped a Inspect for broken or incorrect connec tions Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC olo O o Fle 58 n o G iz g 9 e E 3 2 ol oO EC x Return to Section TOC Return to Master TOC F 12 F 12 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued FIGURE F 2 CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS MACHINE FRONT BACK OF CONTROL PANEL 1 LEAD 231 CONNECTION METER PROBE RIGHT SIDE VIEW 6 Test for 115VAC between leads X1 and 231 NOTE If the main AC input supply voltage varies the control transformer voltage will vary by the same percentage a Connect one end of an insulated alligator clip to the X1 connection at the input con tactor CR1 coil See Figure F 2 Connect the other end of the alligator clip to one of the meter probes Be sure that neither the alligator clip nor the meter probe touches any metal surfaces Connect the other meter probe to the 231 connection top lead at the power switch See Figure F 2 Apply input power to the CV 400 INSULA
117. ting any machine damage After the ground is cleared the fuses automatically reset within a few seconds Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o EE 58 n o G AIS g 8 cic 3 2 ol oO cc a Return to Section TOC Return to Master TOC Return to Master TOC E 5 E 5 THEORY OF OPERATION FIGURE E 5 SCR OPERATION CATHODE ANODE GATE I I I I I I i KR OUTPUT i I NOTE AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE I THE SCR OUTPUT d IS DECREASED ll Rte SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large currents to a load An SCR acts very much like a switch When a gate sig nal is applied to the SCR it is turned ON and there is current flow from anode to cathode In the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes current only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the ON state a
118. to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC o O 2 o o 8 E x 3 2 x Return to Section TOC Return to Master TOC Q O Hr E 7 x 3 o x C 2 ACCESSORIES OPTIONS ACCESSORIES The following options accessories are available for your CV 400 from your local Lincoln Electric Distributor FACTORY INSTALLED OPTIONS Diode Option This internally installed option allows use of the cold start and cold electrode sensing fea tures of the NA 3 NA 5 or NA 5R automatic wire feed ers See the topic Connecting the NA 3 NA 5 to the Ammeter and Voltmeter Display output current and voltage when welding FIELD INSTALLED OPTIONS The following options accessories are available from your local Lincoln Distributor Undercarriage K817P Includes a platform and polyolefin wheels for easily moving the welder Undercarriage K841 Includes a platform wheels and brackets for supporting the welder and two gas cylinders Remote Output Control K775 or K857 with K864 Adapter Plug The K857 has a 6 pin MS style con nector The K857 requires a K864 adapter cable which connects to the 14 pin connector on the CV 400 The K775 consists of a control box with 28 ft 8 5m of four conductor cable This connects to terminals 75 76 and 77 on the terminal strip and the case ground ing screw marked with the symbol 777 on the machine
119. tuck coils with the top iron 6 The leads from the coils that are to be removed and or replaced must be discon nected See the Wiring Diagram When aluminum leads are re connected apply a thin layer of Dow Corning 340 Heat Sink Compound Lincoln E1868 to mating surfaces IDEALARC CV 400 LINCOLN B F 49 F 49 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 27 EPOXY MIX APPLICATION AREAS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC REASSEMBLY OF TRANSFORMER COILS NOTE The following procedure describes a complete replacement of all primary and sec ondary transformer coils Adapt the procedure for the specific coils you may be replacing 1 Apply a coating of Lincoln Electric E2547 Epoxy Mix along both sides of the bottom iron lamination assembly in the areas where the coil sides will be mounted Coat the areas no closer than 38 inches from the top edge of the iron See Figure F 27 arrows Be sure that none of the epoxy drips onto the top of the iron assembly where it will meet the top assembly Ojo O o Fle 58 n o G iz D mlt 3 2 ol cc a Return to Section TOC Return to Master TOC IDEALARC CV 400 LINCOLN B F 50 F 50 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued Return to Section TOC Return to Master TOC Return to Section TOC Ojo
120. used Set ing properly A low battery can affect the voltmeter scale low at approximately 0 5 results of the test Repeat Battery Test volts or 0 10 volts Procedure in Step 10 if needed 10 Test the voltage level of the battery Short 16 Open switch SW 1 leads A and C Close switch SW 1 Battery voltage should be 4 5 volts or higher 17 Reconnect the tester leads See Figure F 16 If lower replace the battery a Connect tester lead A to the cathode 11 Connect the tester to the SCR 1 as shown in b Connect tester lead C to the anode Figures Fis c Disconnect test lead G from the gate 5 7 a Connect tester lead A to the anode 18 Close switch SW 1 3 b Connect tester lead C to the cathode 19 Read meter for zero voltage Bm E Connect testerlead ato te gate a If the voltage is zero the SCR is func SIE 12 Close switch SW 1 tioning E NOTE Switch SW 2 should be open b If the voltage is higher than zero the SCR is shorted 20 Perform the Active Test Procedure outlined in Steps 11 19 for SCRs 2 and 3 21 Replace all SCR assemblies that do not pass the above tests 13 Read meter for zero voltage a If the voltage reading is higher than zero the SCR is shorted 14 Close or keep closed switch SW 1 15 Close switch SW 2 for 2 seconds Release and read metet 22 Replace all molex plugs onto the control board and snubber board Reconnect posi a Ifthe voltage is 3 6 volts wh
121. ut will be zero the amber thermal pro tection light will be on and the fan will continue to run The secondary thermostat will open either with an excessive overload or insufficient cooling The output will be zero the amber protection light will be on and the fan will continue to run When the thermostats reset the protection light will be off The power source is also protected against overloads on the SCR bridge assembly through the solid state fault protection circuit This circuit senses an overload on the power source and limits the output to approxi mately 550 amps by phasing back the SCR s Protection is provided to protect the circuitry from acci dental grounds If leads 75 76 or 77 are accidentally grounded to the positive output lead the output will be reduced to a low value thus preventing any damage to the machine If the ground occurs between 75 76 77 and the negative output lead one of the PC board elec tronic self restoring fuses will blow preventing any machine damage After the ground is cleared the fuses automatically reset within a few seconds AUXILIARY POWER On machines above code 9400 the IDEALARC CV 400 can provide nominally 115 volts AC and 42 volts AC auxiliary power for operating wire feeding equip ment and other accessories This power is available at the 14 pin amphenol on the control panel and or at the terminal strip behind the hinged control panel on the case front On the amphenol 115
122. visions for parallel duty cycle is exceeded a thermal protector will shut off ing It should not be used outdoors without rain shel the machine output until it cools to normal operating tering temperature The amber thermal protection indicator light will turn on until the machine cools Duty Cycle Amps Volts 100 400 36 60 450 38 50 500 40 Based on a 10 minute time period For example a 60 duty cycle means 6 minutes on and 4 minutes off IDEALARC CV 400 LINCOLN B OPERATION CONTROLS AND SETTINGS All operator controls and settings are located on the case front assembly See Figure B 1 for their locations FIGURE B 1 CASE FRONT CONTROLS o O c 9 o o o 8 c x 5 o x Return to Master TOC O O Awanu ro O O lO MM AME N 17 Wi S 8 9 d 2 DE cle Pa d 1 POWER SOURCE PILOT LIGHT 6 DC AMMETER 2 ON OFF POWER TOGGLE SWITCH 7 AUXILIARY POWER CONNECTIONS FOR WIRE FEEDER AND 3 OUTPUT CONTROL POTENTIOMETER OTHER EQUIPMENT 115V AND 42V 4 OUTPUT CONTROL SWITCH WITH LOCAL OR 8 VOLTMETER ELECTRODE OR ELECTRODE SWITCH REMOTE POSITIONS 9 THERMAL PROTECTION INDICATOR LIGHT 5 DC VOLTMETER 1 POWER SOURCE PILOT LIGHT This light indi 7 AUXILIARY POWER AND REMOTE CONTROL cates that the power source input conta
123. without removing the case cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC CV 400 LINCOLN B Return to Section TOC Return to Master TOC Return to Section TOC olo O o F 58 n o G AIS g 8 SIE 32 ol aja Return to Section TOC Return to Master TOC Return to Master TOC

Lincoln Electric IDEALARC SVM136-A User's Manual

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