Home

Lincoln Electric IDEALARC CV-400-I User's Manual

1. ___ H3991H1 9 NOLLO3NNOO SISSVHO GND 8 F OA G NOILONNA QuvaNvIS Nid LNAWdINOA HNOA NI LN3S3Hd 38 LON AYN AYA HOV3 ATNO 031511 SHV SNOILONNA SSSHL INVHOVIG ONIHIM 21VIHdOHddY 339 4317349 dO OV daivad 38 ISNN GOHLAW ONILVINSNI JHL H31dVOV IVSddAIN NI qva31 GASANN ANY 0380 HOv3 SLVINSNI ANY Q3gino3d Sv SNOLLO3NNOO 0105 321145 on3sn SNOILO3NNOO 3XVIN OL H3Sf1l AHL MOTIV OL 93391530 SI vL V HOIHM S39unoS YAMOd NIOONIT HLIM 0951 38 OL LNVAW SI HOLO3NNOO SIHL Z 4399141 ANY 3uvdS H3d 13M 3H1 AGISNI SLINOYIO LN3GN3d3GNI 31771051 38 LON AYN AVN OV Ave Cr Lv Ov AZ ce 18 OV ASLL ALON MO 138 NMOHS 38V SNOILONN ANY SNOILVNOISA Nid HOLOANNOO QHVONVIS d3ldvQv TWSYSAINN OL SNOLLO3NNOO JHL SAVHOVIG ONIYIM LNANdINDS ALVIYdOUddV 3HL LIASNOOD 31gVO 4230333 34IM OL H31dVQV SIHL ONITIVISNI 380338 410 394N0S H3MOd ONIGTAM dH1 dO HOLIMS H3MOd JHL L NOLLVH3dO 430334 341M d3dOtd 804 GAYINOAY AdH1 38V 39unOS H3MOd NI 1395399 SLINOHIO TIY LON HLIM Q3S 38 TIIM 431dVOV SIHL 830334 38IM ANY SONOS YAMOd SHL dO WVYOVIC ONIYIM JHL LINSNOO d19V1d3O3H 830334 38IM JHL NI 195399 SLIN9819 vL AHL dO ANY OL SNOILONYLSNI NOILVTIVISNI 3 19V1dd9d4d 430333 d8IM V 400 I LINCOLN E
2. U31dVOV TVSH3AINRQ 498 KUM 4JO9Vld39438 H30333 3UIM NId 39UN0S uaMOd N OONITI _091 0 39800S u3MOd 139 01 SLOVINOD 30 13S Y 35070 LVHL SH30333 381 803 vu9vIQ CV 400 I LINCOLN E F 12 S 13QON NO NOILVENDIANOO FIGNVH E N ee SMA49S 91 9 ONISA NMOG H3Q HM ONILNNOW 401 3SV8 NI 510195 HNO VN VN vc 00 009 29 2 i GSYALNIO 86 32 21 DIAGRAMS DIMENSION PRINT ogg 09 21 8 02 61 66v S9 6L voe 66 LL 099 00 92 609 0 0 9501 89 Ly 66 06 F 12 CV 400 I LINCOLN E Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Draw
3. ccce Per Section A Technical Specifications su A 1 Select Suitable LOCation ss ua sicci ceat cedere eae Leda Ced EE Tad A 2 Input Connections siens A 2 Field Installed Options uu uu aed A ee A 3 Required Equipment Control Cable Connections A 3 Output Connections u S ua ack oni a i a tiie eevee A 3 Fear u PAE LEM D ip E EL dec A 4 Connection of Auxiliary Equipment to Wire Feeder Receptacle A 4 Section B Safety Precautions iii B 1 General Description erred eed ie rab oce sica Meee B 2 Recommended Processes and Equipment sss B 2 Operational Features and Controis B 2 Design Features pM B 2 AEEA EENE AEEA E B 2 Power Source Operation iii B 2 Bye reece cert ne d ey rrr erer 2 Controls and Settings iii B 3 Graphic Symbols ed Me eee B 4 Output Panel Connections sisi B 5 Case Back Connections iini u sassa o eed erie ices B 6 Starting the Machine ss B 7 Adjusting the Output Voltage using the Digital B 7 Local Remote Switch Operation B 7 nudis dom B 7 Overload Protection sise B 7 ACCOSSOMICS Section Factory Field Ins
4. 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 VE ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5 b material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitabl
5. control circuit sary Malfunctioning Remote Control See Options Troubleshooting Faulty Control PC board See PC Board Troubleshooting Procedure Poor arc striking with semiautomatic 1 Poor work connection Work connection must be adequate wire feeders for application Improper procedures Adjust procedures for improved start ing Wire feed acceleration too fast or 3 Adjust wire feeder acceleration set too slow ting if provided Defective PC Board See PC Board Troubleshooting Procedure Poor arc characteristics 1 Control PC Board defective 1 See PC Board Troubleshooting Procedure CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual OPTIONS TROUBLESHOOTING GUIDE K857 or other Remote Output Control PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS Output control not functioning on 1 Local Remote switch in wrong 1 Place switch in Remote Remote Control position Faulty Local Remote switch Faulty Remote Control poten tiometer Leads or connections open in control circuit Faulty Control PC board
6. 1 Check 2 and 4 circuit wiring Repair connection See PC Board Troubleshooting Procedure Turn power off Remove output short circuit Check for continuity between pins C amp D in the K484 a Turn power off to clear error Use recommended wis voltage set tings and angle of approach of wire to work b If problem still persists call Local Lincoln Authorized Field Service Facility Voltage Control wiring Check wiring and control and PC board wiring harness plugs See PC Board Troubleshooting Procedure Check and replace potentiometer if faulty Check wiring of lead 75 CAUTION If for any reason you do not understand the test procedures or unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS Thermal Protection Indicator light is 1 Thermostat circuit has opened Allow machine to cool Be sure to on provide adequate ventilation for machine Faulty Control PC Board See PC Board Troubleshooting Procedure Machine does not have maximum Faulty Control PC Board See PC Board Troubleshooting output Procedure Voltage Adjust potentiom
7. LIM TOHLNOO 310IN3H 1 688 ONISN dl QN 314v9 NO A18N3SSV 13103NNOO LON 031911 LON SNid O N 318vO LNdNI 1149 3004193173 ALIHV10d u3dOHd OL CENT HHOM OL YAMOd NO HOLIMS ALIBY Od 1 430334 SHIM 13S ANY SONOS H3MOd 1V S3T8VO 300812313 3SH3A3D 440 H3MOd NENL ALYY TOd SONWHO OL 3AlISOd 300819313 SMOHS INVHOVIO H N NOILVOlrIdaV dO 319A9 ALNG NV JAN3uudno dOd 032415 34 LSNW 318VO SNI A VN 42023 jdIM _ lON3HdMWV MOOHS Nid vL QUIYORW SIY 991195 91919919 10 asn suosJed paylenb JOYNOS H3MOd ayy Dunoeuuoo eJojeq eonog 1 MOd N IOONIT e DNINEVM Y au uo U91IWS 18mod au 0 yo uin e CV 400 I LINCOLN E DIAGRAMS F 9 K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS F 9 98615 06 91 6 M3IA LNOYS ON Id 318VO Nld v L ANY MJM uv3d 7319143914 4 L8 v 6871 O QN9 8 ce V aan 9 0 3dVdS N Lv LEP MJA Ofrid 318VO Nid 7b ANY M3IA LNOYS 310v1d393H Nid 7t L8 9 E 9 70 ps 3juVdS N 5 LZ H 281 adi AN9 8 Le f Z8 V d a Pv ve SUVS N JOHINOO 3Q0W PNA 18 TOHLNOD 3gON S 9NQ A z8 1 X 16 r l 1 H _ jodiNOO INdINO sz 9 TOHLNOO 1ndinO 9 4 TOHLNOD 1hdinO 74 3
8. 10096 400 Amps 36 Volts at 60 Duty Cycle is based on operation for a 10 minute period CV 400 I LINCOLN P B 3 CONTROLS AND SETTINGS OPERATION B 3 All operator controls and adjustments are located on the case front of the CV 400 I Refer to Figures B 1 and B 2 and corresponding explanations FIGURE B 1 CONTROL PANEL ta v A Samer Em VOLTMETER 27 O roca A POWER SWITCH B VOLTAGE ADJUSTMENT C THERMAL PROTECTION INDICATION LIGHT D VOLTS AMPS SWITCH E DIGITAL VOLTMETER AMMETER A POWER SWITCH A two position toggle switch Controls the input power to the CV 400 I B VOLTAGE ADJUST Controls the CV 400 I output voltage C THERMAL PROTECTION INDICATION LIGHT Indicates that the protection thermostat has activated The digital meter will display E10 when this occurs When the light turns off the machine will be capable of supplying welding output power again NOTE Leaving the power switch in the ON posi tion will result in the most rapid cooling D VOLTS AMPS SWITCH Selects either output current or arc voltage to be displayed on the digital meter E DIGITAL VOLTMETER AMMETER Displays the CV 400 I output current or the arc voltage 42 VOLT CIRCUIT BREAKER 115 VOLT CIRCUIT BREAKER LOCAL REMOTE SWITCH WIRE FEEDER VOLTMETER SWITCH NOTE Due to voltage drops in the welding cables and at cable connection poin
9. Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR LiH 2 T ff Chi suc e J T p gt 7 Z gt b lt NTUWSHILT FSU E GUB DERNIERE see Oa CRM ER ecu SHBg Xe sd s Bp HZA e 2x9 Weal AMI d ous uil el jay oa Y O 1 gl uit ae celal AL usu DA dax Y Jio moe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOOM COREE CIE REA e i8 9 MR Pam SEL fF35 FF o eis A Jo ALD al gll pis Ac AI uie Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo e A HAUSHERMRELTTF EU RRR HEBS SOSRSHR ez 119 Bo Soares s ESSAI de ule Lily vues al ad ne t daag READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR
10. D WIRE FEEDER RECEPTACLE 14 pin MS style receptacle for wire feeder Provides connections for auxiliary power contactor closure remote output control wire feeder voltmeter sense lead and ground OPERATION B 6 CASE BACK CONNECTIONS FIGURE B 3 BACK PANEL A 220 VAC RECEPTACLE C CABLE CLAMP FOR INPUT CABLES B CIRCUIT BREAKER A 220 VAC RECEPTACLE loads and shorts If this breaker opens the CV Continental European type nonpolarized ground 400 1 will work normally however equipment pow ed receptacle also known as a Schuko type for ered by the 220 volt receptacle will not work connection of water coolers or other equipment C CABLE CLAMP FOR INPUT CABLES B CIRCUIT BREAKER Protects the 220 volt auxiliary circuit from over CV 400 I LINCOLN B 7 OPERATION B 7 STARTING THE MACHINE The power switch at the extreme right side of the con trol panel energizes the CV 400 I ADJUSTING THE OUTPUT VOLTAGE USING THE DIGITAL METER The digital meters in the CV 400 I incorporate a voltage pre set function This allows the operator to set the desired welding voltage before striking an arc The digital meters can also display welding current To make use of the voltage preset function the Volts Amps switch must be in the Volts position Turn the Voltage Adjust knob until the digital meter displays the desired weld ing voltage See below if an external power source remote control is installed Wh
11. EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU e Fat ie es EUR Es fE ie B sk HE e zzv 24758 else 8xbiogst SUAS MAS sis PARAH 387E Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier
12. F 10 DIAGRAMS F 10 TWIST MATE CABLE PLUG INSTALLATION INSTRUCTIONS TWIST MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS A WARNING 15 eco Ker Ni IR e TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING PLUGS ON CABLES OR WHEN CONNECTING OR DISCONNECTING PLUGS TO WELDING POWER SOURCE 1 CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE APPROPRIATE CABLE SIZE PER TABLE BELOW AND SKIN CABLE JACKET TO LENGTH SPECIFIED AMERICAN EUROPEAN RANGE BOOT MARKING CAN EUROPEAN RANG CABLE SKIN LENGTH 35 50 2 4 35 50 mm 1 INCH 25 4mm 50 70 1 0 2 0 50 70 1 INCH 25 4mm 70 95 2 0 3 0 70 95 1 5 INCH 38 1mm If necessary trim cable end of boot at groove s to match cable diameter Boot must fit tightly enough to seal around outside diameter of cable NOTE Some boots are designed to accommodate different cable diameters without trimming These boots do not have grooves at the cable end Soap or other non petroleum based lubricant will help to slide the boot over the cable Slide rubber boot onto cable end BOOT WELDING CABLE SEE TRIM 4 Slide the copper tube into the brass plug SET SCREW 5 Insert cable into copper tube 70 95 size may have 2 set screws BRASS PLUG COPPER TUBE f16 00 6 6 Tighten set screw s to collapse copper tube Screw s must apply firm pressure against welding cable The top of the set screw s will be nearly flush or b
13. euiuoeu eui episui pejsed si epoo sejnomed 104 Jenueui siy Aq peJeAoo 40 e1eunooe eq jou AjUO 104 SI ureJBerp SIUL 82681 S3NIHOVIN A009 086 40 51100 AHVNIHd WOLLOG 3HL NO HV3ddv 4 NV 3 SQv31dVL O N KINO S3NIHOVIA A009 08 ANY A00 002 ASL HOS HANHOASNVEL NIVIN JHL LV GVW SI NOLLO3NNOO 1N3NVIAH3d SIHL 8 N H313WOILN310d 40 G3M3IA 9NIBIM V N HOV3 QHIN 000 1 9 19 sr er or ir Nid Ob Nid 8 Nd9 N etc oTr 9 6 1 2 1 tal 21 quvo8g 9 d JO 301S LN3NOdWOO 30N3003S SNIH3SWRN ALIAVO HOLOANNOO 26913 Wad SNOILOSNNOO S 108NAS 1vOIH1033 ANOLSND 310V1d3938 HIHVIHS LINOHIO ve 50 S2 109 20 Mi Log d Ags LIN9HI9 YS go 3INHOJSNVHL NIVIN HOLIMS INN 15 Pa HOLIMS NTIS OL ez ad 1 gd TANVd 193NNOO3H 193NNOO3U l S39V110A 1 dNI 009 002 HOMS IS OL 1 1 HON aN gt 1 1 2093 NOILISOd SLTOA NI NMOHS Y Sd SITOA zs 210 04 7 uides 121 yar e b 012 lt ke 8 OWA Zr lt S313 ps 607 d v vr ze ar 23 802 4e SI b 102 4 9 jf tie MENT No 4 9 2
14. listed above the error condition still exists the problem may be with the wiring in the following areas the shunt leads 218 and 219 or voltage feedback leads 213B 214B and 224B CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual MACHINE TROUBLESHOOTING GUIDE Not all trouble conditions can be recognized by the PC board and displayed as error codes The following guide covers most other trouble conditions PROBLEMS SYMPTOMS PROBLEMS Machine has no output 1 Secondary contactor circuit 2 and 4 wire feeder receptacle not working Electrode or work lead loose or broken Defective PC Board Protective circuits operating due to output short circuit If using an LN 25 K484 jumper plug kit not making connection between 2 amp 4 in wire feeder receptacle If welding with 1 16 aluminum Machine has minimum output and no 1 wire and machine is flashing EOO Voltage Control misconnected Open in feedback circuitry Faulty PC Board 3 Voltage Adjust potentiometer circuit open lead 75 POSSIBLE AREAS OF RECOMMENDED MISADJUSTMENTS S COURSE OF ACTION
15. running EN 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side SD K 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 work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 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 sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder
16. 000 L 70 10 05 gr er or rr IS Nid 9 om Nid OF Nid 8 0000 104 eq jou y AjUO JO SI SIUL LON I WU3AHOJSNVHL NIVIN 10910 Nt 10920 21 4 1 E VOS 9 d 40 3015 IN3NOdWOO JONANOAS ONIHIANNN ALIAVO HOLO3NNOO 2919 Wad STOSWAS 1VOIH19373 SNOILO3NNOO SWOLSNO 310193939 HOLIMS INN 15 7 HOLIMS INN IS 7 u30333 TU In T annoys g 1151 y zr Od ona d gen saaw Iv l Ir NOLLISOd SLTOAs NI NMOHS cce NS UN 7 010 4 2 35x 1 eI auvog y p 010 oh 602 p ON amp s 902 1 602 H 1VISONH3HL 2 2 AHVGNO03S Yasue LINDO VOL go O Ver gt sod ner i vir S LOANNOOSY S39V110A LNdNI 007 06 193NNOO3H lOH1NOO ot 9p 107 er 1 doi 0f 9 9p 002 s CV 400 I LINCOLN E x1 82 inano L SLOPE 930333 LH y p 86i 6 bp 02 A 2 40120 AZL 3 1 zx s 3009 1V9IH19413 TWNOLLWN Yad ANNOH9 WALSAS V OL ia 9 9 6 Now Le LI 4 L b 9 Jis qe s t b vroz ner J 10 HOLIMS oze 875 H313WLTOA 830334 12 gs d
17. 1 92 0 89 ON lt 2 ln M 8 21 INEO 1051309 108110 912 Ac uz Ac grzz Je e Sl2 qe 8 HOLIMS H3LINLTIOA 430334 SHIM 8 NOLLISOd 1V901 NI NMOHS l HOLIMS 310N34 1V001 0 gt 10 QHVOB 0 d TOHLNOO bose ze O Mv igo L ath oN 2 0 O Ver s p 902 1 902 oo H Vr do1id ner pP _LWISONYSHL 20 88 AHVONOD93S vtr 9010 Ags bd DELE 9 p ox I 6 p 02 dol zd Nd ob 202 r p p 9 Pb vroz 1NDHS Awos V 007 a J p rez 022 07 222 WHO 92 222 zz 8 9702 i 103NN0938 103NN0938 TANVd 193NN0038_ 193NN0038 103NNO038 3009 1V9IH193 13 IVNOLLVN Yad W31SAS V OL HOLIMS IS SINN ATddNS LAdNI 1HOdX3 1 AD WVH5VIG ONIHIM ALON CV 400 I LINCOLN E DIAGRAMS F 2 F 2 Jequunu epoo 1u uidinb eu BAIN jueujeoe doi 104 uoWiyedsq BdIAIBS eui 01 1HA lqIB li s au JI sjeued y euo UO euiuoeu y episui pejsed si epoo sejnomed e yenuew siy Aq 29861 96 01 6 UNYI H313WOI1N31Od 40 HV3H Q3MIA ONIBIM ve 82 HOV3 GdN
18. 7 K775 LN 7 699005 ALVINSNI ANY 50731 391195 ATIVACIAIGNI AYF1 GASANN HOV ALVINSNI JOounoS d3MOd LV SATEVO HHOM 3008193 13 3Su3A3H 4401 HIMOd NENL ALIBVTOd 39NVHO OL 3ALLISOd 300819313 SMOHS INVHOVIO 8 N id NOILVO 40 41949 ALNG 1N3HHVO 401 09215 38 LSNW 318VO 9NIQTJM 1OHINO9 ALOWSY QN TWNOILdO S775 L 94 0 G EM 399 NO NO L L y M 0 0 GE o ct Lle LI 3 18vO LAdNI VOV HO 1607 o y Y30334 7 SHIM ON lt o 18 1 N1 o 29 O juvdS SIU 9019 10 esn 5 poys suosJed y eJojeg asn y e yams joeuuoosip ulpa M eur 0 amod e 318V9 3040419713 daldVdv IVSddAIN 298 AOM OL JON3HdNNV TI NV MOOHS 91419373 e ONINEVM Y 3Od OS 43MOd I AO AO CV 400 I LINCOLN E DIAGRAMS F 6 CV POWER SOURCE TO AN LN 25 F 6 199065 6 81 9 YAdWAL v8 JHL N3HM LOH SAVM IV 38V S IVNINd31 SO8NOS d3MOd JHL d3ldVQOV TIOHINO9 310I N38 7989 AHL dO TON3HaWNV Nid vL 3HL OL Ofr1d YAdNAP v879 IHL LO3NNOO 1OHINOO 310IN3H 298 V ONISN dl Q43S SI 1OHLNOO 310IN38 ON dl d3MOd AHL 10 TONSHdNY Nid vL 3HL OL AT19341Q Oft 1d HA
19. C O OFF TION INDICATOR LIGHT m CIRCUIT en o BREAKER AC CLOCKWISE ROTA AY POWER Z TION INCREASES VOLTAGE AC AUXILIARY Ny 1077 POWER lt INPUT REMOTE OUTPUT LOCAL OUTPUT VOLTAGE CONTROL VOLTAGE CONTROL WARNING INDICATES WARNING INFORMATION LOCATED ON RIGHT CASE SIDE CV 400 I LINCOLN P B 5 OPERATION B 5 OUTPUT PANEL CONNECTIONS FIGURE B 2 OUTPUT PANEL A POSITIVE OUTPUT CONNECTION B LOW INDUCTANCE NEG CONNECTION A B OUTPUT CONNECTORS Each connector is a Magnum Twist Mate receptacle Insert a mating Twist Mate plug and twist clockwise to secure For GMAW processes and most FCAW processes the positive output connection goes to the wire feeder One of the negative output connections goes directly to the work A POSITIVE OUTPUT CONNECTION B LOW INDUCTANCE NEGATIVE CONNECTION The low inductance connection is typically used for short arc welding of mild steel par ticularly on thin materials or when using shielding gas CV 400 I LINCOLN P C HIGH INDUCTANCE NEG CONNECTION D WIRE FEEDER RECEPTACLE C HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION The high inductance connection is more suit able for short arc welding heavier weldments or when using 75 Argon 25 CO shield ing gas This connection produces a softer arc and a flatter bead with more wash in than the low inductance connection A spray type transfer is possible with either connection
20. ECT 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 purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 QA 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 9 MAGNETIC FIELDS S may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spi
21. IM501 A IDEALARC CV 400 dem For use with machine Code Numbers 10182 10183 10084 10085 amp 10086 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thought ful 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 carelul EEE OPERATOR S MANUAL ISO 9001 gt ANSI RAB EJ e a ge N Pi Designed and Manufacti Inder Quality Program Cei LINCOLN Copyright 2002 Lincoln Global Inc e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains 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 The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROT
22. 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 remedy possible prob lems with machine setup or operation Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into three main cat egories output problems function prob lems welding problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS If you have exhausted all of the recom mended tests in Step 2 Consult your Local Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely conta
23. RRB sy EZ BU BS 0 A amp oli FAIS HHR ele EFSA BEHE TT Saal gl Cala aui J al gll Gail guet ag ls i LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
24. UNOS H3MOd LV 318VO ANY 3008193 13 3SH3A3H 14401 d3MOd NENL ALIGV1Od SONVHO OL SAILISOd 3008193 1H SMOHS WVHOVIO AN NOILVOITddaV 40 31949 ALNG ANY LN388n0 401 09215 38 LSNW 318 VO ONIQT3M V N 30041911 ON Id OL ud NOILdO L fFPM HLIM WNOLLdO 430334 SHIM Sc N1 d3ildvQVv 310IN3H 798 IVNOILdO JON3HdNV 3ounos d3MOd I AO AO TIN SIY 921 98 MOOHS 10 esn Jesu pinoys suosied p ljl nb e JTE Dunoeuuoo 810 84 y JE yams joeuuoosip au Buisn 891n0S 18M04 Bulpja 0 amod jjo uin e ONIN W INVH9VIG NOILO3NNOO NOILdO SC NT1 OL H3MOd I AD AD CV 400 I LINCOLN E DIAGRAMS F 8 LINCOLN POWER SOURCE TO AN LN 742 F 8 M3IA uv3ad 0719 318VO Nld vL ANY QVAW WW MIA 1 9019 318VO Nid 7b ANY MIA diovid3odu 13700 71 MIA LNOH4 1 1370081 ty pe 9 4 WHOM z H TOHINOD LNdLNO sz TOHLNO9 109110 9 4 JoHINOO INdLNO 4 3 ___ v 4inoHo Z 9 po NOIIONMA ova J Nic AVHOVIC ONIHIM 21VIHdOHddY 335 INAWdINOA YNOA NI 1N4Sdud dd LON AVN AYN HOV3 AINO 3JON383HHH 401 31SI1 38V SNOILONNA v q 6 9 GZ 67 0 LG H Lv NOILISOd 310IN38 OL HOLIMS 1OdLNOO 5 d3MOd LAS
25. Voltage Adjust not functioning on the 1 Local Remote switch in the wrong position Faulty Local Remote switch Faulty Voltage Adjust potentiometer Check and replace if found faulty Check and replace if found faulty Check all leads and connections internal or remote for continuity repair if necessary See PC Board Troubleshooting Procedure Place switch in Local position Check and replace if found faulty Check and replace if found faulty CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN E 7 TROUBLESHOOTING E 7 Procedure for Replacing PC Boards A WARNING e ELECTRIC SHOCK can e Have a qualified individual install and service this equipment Turn the power source input power off at the disconnect switch before work ing on this equipment Do not touch electrically hot parts Before replacing a PC board which is suspected of being defective visually inspect the PC board in ques tion for any electrical or mechanical damage to any of its components and conductors on the back of the board a If there is no visible damage to the PC board install a new one and see if this remedies the prob lem If the problem is remedied reinstall
26. Y product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page InstallatiOri
27. and refer to the instructions included with those options REQUIRED EQUIPMENT CONTROL CABLE CONNECTIONS Follow the instructions below which are appropriate for the wire feeder that will be used LN 7 to CV 400 I a Turn the CV 400 I Power switch to the OFF position b Connect the LN 7 control cable to the wire feeder receptacle on the CV 400 I c See OUTPUT CONNECTIONS for connection of work and electrode cables LN 25 to CV 400 I a Turn the CV 400 I Power switch to the OFF position b Plug a K484 jumper plug into the CV 400 I wire feeder receptacle c See OUTPUT CONNECTIONS for connection of work and electrode cables WARNING The output terminals are energized at all times when the K484 is plugged in LN 742 to CV 400 I a Turn the CV 400 I Power switch to the OFF position b Connect the LN 742 control cable to the wire feeder receptacle on the CV 400 I c See OUTPUT CONNECTIONS for connection of work and electrode cables Connection of Remote Control K857 NOTE The K864 Remote Control Adapter is required to install the K857 Plug the K864 Remote Control Adapter into the power source s 14 pin receptacle Plug the K857 Remote Control into the 6 pin receptacle of the K864 adapter If possible tape the Remote cable to the heavy output leads so they can protect the smaller Remote cable from damage and abuse OUTPUT CONNECTIONS Output cables must have Magnum Twist Mate plugs
28. ct your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed CV 400 I LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual BUILT IN DIAGNOSTIC ROUTINES AND ERROR CODES The CV 400 I Meter PC Board displays error codes when certain trouble conditions exist The error codes trou ble conditions and possible remedies are listed below ERROR TROUBLE REMEDY CODE Output short circuited 1 Turn power off Remove short circuit May be encountered while 2 a Turn power off to clear error Use recommended starting or welding with 1 16 alu wfs voltage settings and angle of approach of wire minum wire to work b If problem still persists call Local Lincoln Authorized Field Service Facility Thermostat circuit has opened Allow machine to cool Be sure to provide adequate ventilation for machine See PC Board Troubleshooting Procedure Voltage Adjust potentiometer not 1 Check wiring between Voltage Adjust and the connected Control PC Board Remote Control not functioning 2 See Options Troubleshooting Guide correctly Input line voltage too low Turn power off Insure machine input voltage is within specifications Turn power back on Input line voltage too high Turn power off Insure machine input voltage is within specifications Turn power back on NM Overload condition Reduce load on machine If after attempting the remedies
29. dNAL 787 LO3NNOO 5 d3MOd JHL dO TONSHdWY Nid 7 SHL OL d3ldVOV 31ONdd 7989 V dO NOILVTIVISNI S38In03H SLOWSY 7S8 dH1 dO ASN O N 3ounos d3MOd LV SATEVO MYOM NV 3008103 13 ASYSASY 4101 39NVHO OL SALLISOd 300819313 SMOHS WVHDVIG E N NOILVOI IddV 40 41949 ALN ANY 1N388fl0 dOd 031415 38 LSNW 318VO ONIQT3M V N 318v9 3d08193 13 OL aN SF porn very CV 400 I LINCOLN E d3ldVQOV 310IN38H 798 IWNOILdO ON JOYENOS YAMOd 4 JON3HdNNV 1O81NOO SLOWS I AO NO 198 TWNOILdO Nid v SIY 921 95 MOOHS 10 esn leysu pinoys suosjed payijenb e 91419213 18p93 y Bunoeuuoo eJojeg esnj AU JE 10euuoosip y e SNINSVM W 8021n0S JAMO Buipjej AU 0 Jemod yndul y0 e DIAGRAMS F 7 CV POWER SOURCE TO AN LN 25 K444 1 F 7 699025 da TIYLSNI SI ON Id dd3dN0 787 JHL NAHM SAVM TV 38V S IVNIIWH3I 4 5 YAMOd JHL Q N 3IONHdd OL HOLIMS 310N3H 1V90 l 194N0 d3MOd JHL HOLIMS H31dVQV SLOWSd 798 JHL dO 310V 1d3O3U Nid 9 FHL OL NOILdO 1 HLIM Sc N1 JHL ON Id 9 LOANNOO H3ldVOV SLOWS 7985 JHL dO 310V1d3938 Nid 7 JHL OL ON Td YAdNAL 8 LOANNOO HOLIMS ALIYW10d S2 N1 HOLIMS JO
30. e 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 9 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 5 6 5 LINCOLN 8 Shielding gases used for arc welding can displace air cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this eq
31. e a standard Lincoln wire feeder order the appropriate input cable for the specific feeder It will make all of the con trol and power connections between the CV 400 1 and the wire feeder WITHOUT the need for a K867 Universal Adapter CV 400 I LINCOLN B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before oper ating the machine GENERAL WARNINGS SAFETY PRECAUTIONS WARNING e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held combustibles ARC RAYS can burn Wear eye ear and body protection Observe additional Safety Guidelines detailed throughout this manual CV 400 I LINCOLN P B 2 OPERATION B 2 CAUTION When using a CV 400 I power source with wire feeders there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger When used with some wire feeders with the electrical trigger interlock in the ON position the arc might restart if the electrode touches the work or ground during these s
32. e feeder recepta cle A 10 amp circuit breaker protects the 42 volt cir cuit from overloads CV 400 I Export machines only can also supply 115 volt AC auxiliary power through the wire feeder recep tacle A 5 amp circuit breaker protects the 115 volt circuit from overloads The CV 400 I can supply 220 volt AC power at 2 amps for powering water coolers or other equipment This auxiliary power is available from the Continental European type receptacle mounted on the case back A 2 amp circuit breaker located next to the recepta cle protects this auxiliary from overloads NOTE Do not use circuits 2 or 4 for control of auxil iary loads The 2 4 circuit is isolated from the 31 32 and 41 42 circuits CAUTION Note that some types of equipment especially pumps and large motors have starting currents which are significantly higher than their running current These higher starting currents may cause the circuit breaker to open If this situation occurs the user should refrain from using the CV 400 I auxiliary power for that equip ment OVERLOAD PROTECTION This welder has thermostatic protection from exces sive duty cycles overloads loss of cooling and high ambient temperatures When the welder is subjected to an overload or loss of cooling a thermostat will open This condition will be indicated by the illumina tion of the yellow Thermostatic Protection Light on the case front see Figure B 1 The fan will continue to r
33. ected 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 P l 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 iv SAFETY iv PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n ra
34. eder or remote connections or other equipment Do not touch electrically hot parts Always connect the Idealarc CV 400 I grounding terminal located on the welder base near the reconnect panel to a good electrical earth ground SELECT SUITABLE LOCATION Place the welder where clean cooling air can freely circulate in through the side louvers and out through the rear louvers Dirt dust or any foreign material that can be drawn into the welder should be kept at a minimum Failure to observe these precautions can INSTALLATION INPUT CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the welder nameplate Gain access to the input reconnect panel by removing the right case side of the CV 400 I side nearest to the Power switch Have a qualified electrician connect the input leads to Li L2 and L3 of the input reconnect panel in accor dance with the National Electrical Code all local codes and the connection diagram located on the inside of the right case side Use a three phase line The frame of the welder must be grounded A ground terminal marked with the symbol located on the base of the machine is provided for this purpose See the National Electrical Code for details on proper grounding methods Fuse the input circuit with the recommended super lag fuses Choose an input and grounding wire size according to local codes or use the following table Delay type circuit breakers
35. elding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders CHECK ONE _ Please Invoice only if order is over 50 00 _ Check or Money Order Enclosed U S Funds only 1 Credit Card a Account No USE THIS FORM TO ORDER sooks OR FREE INFORMATIVE CATALOGS Titles Price Code Quantity Cost New Lessons in Arc Welding 1 incon Welding School ED 80 Seminar Information Procedure Handb
36. elow the surface of the brass plug after tightening 161815 7 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle CV 400 I LINCOLN DIAGRAMS F 11 CONNECTION OF NON LINCOLN WIRE FEEDERS F 11 O3qQIAOHd 38 LSNW JOVLIOA LVHL HOS AlddfS H3MOd NV S3NIHOVW 3WOS NO O V A SII HO O V A Zh NVHL HSHLO 3OVLIOA LNdNI NV S3uInoO3H H3Q334 3HIM 3HL JI Q3 NnOu9 A dd3dO0Bd 38 LSNW 39HN0S H3MOd q 3HL 03114905 SI LWHL 3DVLIOA 3WvS 3Hl HO4 Q31VH 38 1500 1102 AV 3H 9 g S3NIHOVW NO iN3S3Ud 38 LON AW CE QNV LE SNOIIO3NNOO 0391003 OS 41 83033434M N102N11 NQN 10U1N02 179109 310 34 ON N N 104170 36105 WHO Ol INN u380d 139 01 u30333 IYIN 031739415 JOVLIOA 390 AT YYMON 49V1N09 30 LL 91 SL s UN lt Ib zE RS 2 b Adal TS TVA e SII TOYLNOD OLIVLNOI 104100 H31dVGV 98 3194193939 430331 3HIA NId 39UN0S YAMOd NIOONII FLNdLNQ 328 0 3 04 139 OL 39Y170A V AlddfS 530334 3HIN 803 NYHOYIG 830333 3HIM 0341103 OS 31 8303333818 N102NI1 NON WYLNOD 109119 nos 104170 310m3U 13 H ARS PISE 35012 S13Y1N02 WHO X OI W3MOg LANI b3033i Fula 11 9L SL QON 17 V N 1081N02 B012V1NOJ 104100
37. en an arc is struck the digital meter displays the actual welding voltage as measured at the CV 400 I output termi nals NOTE The arc voltage at the electrode may be as much as two volts different from the CV 400 output terminal voltage This is due to voltage drops present in the welding cables cable connections and welding gun To minimize these drops use cables of ade quate capacity and make sure all connections are clean and tight Because of these voltage drops you may have to preset the CV 400 I for a slightly higher welding voltage than your procedure calls for To read welding current set the Volts Amps switch to the Amps position The welding current will be displayed whenever an arc is struck LOCAL REMOTE SWITCH OPERATION If voltage control is desired at the CV 400 I the Local Remote switch must be in the Local position The Voltage Adjust on the front panel can be used to adjust the CV 400 I output The remote control even if connected will have no effect if the switch is in the Local position To use a remote control such as the K857 see INSTALLA TION section place the Local Remote switch see Figure B 1 in the Remote position The remote control now con trols the output voltage in the manner described above This control may be adjusted while welding to change the CV 400 I output AUXILIARY POWER 42 volt AC auxiliary power as required for some wire feeders is available through the wir
38. er protected 115 VAC 5 amp auxiliary power available for the wire feeder circuit breaker protected Except Code 10182 220 VAC 2 amp Auxiliary power available for water cool ers using standard Continental European receptacle Magnum Twist Mate output receptacles Single MS type 14 pin connection for wire feeder Solid state controls with line voltage compensation Optional remote control capability DESIGN FEATURES Clean appearance and simple controls easy to operate Electronic and thermostatic protection from overloads Submersion dipping of assembled transformer choke and rectifier in special sealing insulating material gives extra pro tection against moisture and corrosive atmospheres Microprocessor based Control PC Board has built in diagnostic routines Compact size requires only 19 x 26 footprint Modular construction for easy servicing Recessed panels protect output studs and controls Large safety margins and protective circuits protect rectifiers from transient voltages and high currents LIMITATIONS The CV 400 I is intended only for use with the follow ing FCAW electrodes NR 152 NR 211 NR 203 Ni 196 NS 3M Outershield 70 and 71 The machine has been designed primarily for the GMAW process POWER SOURCE OPERATION Be sure the CV 400 I is properly installed and that all accessories are properly hooked up before attempting operation DUTY CYCLE 300 Amps 32 Volts at
39. eter Check and replace if faulty defective Voltage Adjust potentiometer Check and repair broken leads leads open Machine will not shut off Replace Variable or sluggish welding arc 1 Poor work or electrode Check and clean all connections connection Welding leads too small Check table in this manual Welding current or voltage Check procedures for recommended too low settings Defective SCR bridge Check and replace if defective Digital meters do not light Faulty Meter PC board See PC Board Troubleshooting Or Procedure Digital meter display is incorrect Faulty Control PC Board See PC Board Troubleshooting Procedure CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS Output Control not functioning on the 1 Local Remote switch is in 1 Move switch toggle to the Local the Remote position position Faulty Voltage Adjust Check and replace if found faulty potentiometer Check lead continuity and connec Leads or connections open in tions for an open and repair if neces
40. everal seconds GENERAL DESCRIPTION The CV 400 1 is a constant voltage DC power source designed for the GMAW process with limited FCAW capabil ity as well It features an international rating of 400 amps 36 volts at 60 duty cycle It also has the capacity to run at 300 amps 32 volts 100 duty cycle The CV 400 I is available as a European model with 42 VAC auxiliary power only or as an export model with both 42 VAC and 115 VAC auxiliary power No options are available other than input voltage The European model of the CV 400 1 features an all graphic nameplate and has an IEC 974 1 Rating for use in envi ronments with an increased hazard of electric shock RECOMMENDED PROCESSES AND EQUIPMENT The CV 400 I is capable of solid wire welding within the rated output capacity of the machine It is also capable of welding with the following flux cored wires NR 152 NR 211 NS 3M NR 203 Ni 1 and Outershield 70 and 71 The CV 400 I Export is recommended for use with the LN 7 LN 742 and LN 25 wire feeder models The CV 400 I European does not provide 115 VAC auxil iary power for the LN 7 models OPERATIONAL FEATURES AND CONTROLS Two inductance positions operator can choose the optimum output characteristics Solid State Output Contactor no noise no moving parts to wear Digital Voltmeter Ammeter is standard Power on off switch 42 VAC 10 amp auxiliary power available for the wire feeder Circuit break
41. for connection to the CV 400 I Order K852 95 for connecting 2 0 3 0 70 95 mm2 cables Refer to S18737 for instructions on installing these plugs Use the shortest possible cable lengths See Table A 1 for recommended cable sizes based on length Connect the positive output lead to the terminal marked The negative output lead can be hooked to either the low inductance terminal marked f A or the high inductance terminal marked ANNAN TABLE A 1 Cable Sizes for Combined Lengths of Copper Electrode and Work Cable Lengths up to Machine Size 150 ft 150 to 200 ft 300 A 100 400 A 60 2 0 70mm 3 0 95mm CV 400 I LINCOLN Ag INSTALLATION PARALLELING The CV 400 I is not designed to be paralleled with any other power source CONNECTION OF AUXILIARY EQUIPMENT TO THE WIRE FEEDER RECEPTACLE Occasionally it may be necessary to make connection to the circuits present in the 14 pin wire feeder recep tacle These circuits such as the auxiliary voltage contactor and remote control circuits may be accessed with a K867 Universal Adapter This adapter plugs into the receptacle and provides the user with short wire leads for connections Refer to the instructions provided with the K867 as well as the wiring diagram for the CV 400 I power source for details on making those connections For your conve nience wire feeder connection details are shown in the DIAGRAM section NOTE If you intend to us
42. ings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the W
43. iping 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode LEM Sr if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 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 subj
44. kz or 9 9 ry u v8 I QHVO8 9 d NOLLISOd 1901 NI NMOHS O81NOO HOLIMS 310W3H 1V901 6L 9712 aa OORT poor v Qo 9812 VELO m 9 vrez LNNHS Awos V 00 cp p uz 122 O r p rzz M 022 rca WHO 2 b 002 C 5 2 0 1 00 AD INVHOVIG SNIHdIA F 3 29902 394N0 d3MOd JHL AO TONSHdNV Nid 7 JHL OL 431dVOY 1 6 81 9 jLON3H 798 V dO NOILVTIVISNI SHL SAYINDAY 1OHINOO 310IN3H 298 3HL dO 3SN O N 4401 H3MOd NENL ALIHV TOd SJONVHO OL dALLISOd 3004197713 SMOHS WVHDVIG AN NOILVOI IddV 40 319A9 ALOG ANY LN388f10 804 GAZIS dg LSNW 318VO SNI HA DIAGRAMS CV POWER SOURCE TO AN LN 7 AND K857 F 3 j18vo 3004193713 OL 18IN3SSV 1 dNI 0872 d31dVOv IOHLNOO J1O0NN3H t98 IWNOILdO 43033 JjdIM VAIDZ N1 Z N 1 JOdLNOO 310IN3H 198 IWNOILdO jounos d3MOd JON3HdIAV AOAO Nid VF TH BUIYDEW SIY 9210195 MOOHS 10 SN Su Pinoys suosied peyiyenb e 18D99 eJojeg esni au 1 YOIMs au e ONIN W 80JNOS 18M04 BUIPISM AU 0 Jamod indui 40 UN e CV 400 I LINCOLN E DIAGRAMS F 4 CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER F 4 859005 6 81 9 43033 OL JN PV T
45. lar intervals to eliminate excessive dirt and dust build up on inter nal parts MACHINE AND CIRCUIT PROTECTION The CV 400 I Control PC Board has built in diagnostic routines to alert the operator when trouble exists When a trouble condition occurs the CV 400 I meter will display an error code in the form EXX where XX refers to a specific error See TROU BLESHOOTING section for an explanation of the error codes The power source is thermostatically protected against overload or insufficient cooling If the machine is overloaded the thermostat will open thermal pro tection indicator light will turn on and the output will be zero The fan will continue to run and auxiliary power will still be available The thermostat will remain open until the machine cools at which time it will close and the output will again be available The CV 400 I is electronically protected against over loads and accidental short circuits The overload pro tection circuit automatically reduces the output current to a safe value when an overload is detected If the circuitry senses a short circuit it will shut off the CV 400 1 output The short circuit protection circuit can be reset by turning the CV 400 I Power switch OFF for at least 10 seconds Remove the short before turning the Power switch ON again CV 400 I LINCOLN TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by
46. les suivantes 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 metallique 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 defonctionnement 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 machine 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 pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lunettes avec crans lateraux dans les zones o
47. lled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and 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 equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety nes alle minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is
48. may be used in place of fuses Using fuses or circuit breakers smaller than recommended may result in nuisance tripping from welder inrush currents even if not welding at high cur rents RECOMMENDED INPUT WIRE AND FUSE SIZES Type 75 C Input Type 75 C Copper Ampere Copper Wire in Ground Wire in Rating on Conduit AWG Conduit AWG IEC Sizes IEC Sizes mm result in excessive operating temperatures and nuisance shut downs Idealarc CV 400 I power sources carry an IP23 enclosure rating They are rated for use in damp dirty environments subject to occasional falling water such as rain Fuse Super Lag or Breaker Input Voltage Frequency 208 60 460 60 575 60 STACKING The CV 400 I may be stacked three high provided the bottom machine is on a stable hard level surface Be sure that the two pins in the roof fit into the slots in the base of the CV 400 I above it 200 50 60 220 50 60 EC 380 50 60 415 5080 50 Also called inverse time or thermal magnetic circuit breakers circuit breakers which have a delay in tripping action that decreases as the magni tude of the current increases TILTING Do not place the machine on a surface that is inclined enough to create a risk of the machine falling over CV 400 I LINCOLN A 3 INSTALLATION A 3 FIELD INSTALLED OPTIONS For installation of compatible field installed options see the ACCESSORIES section of this manual
49. o display E00 The CV 400 I power switch must be turned OFF and then ON to return the machine to normal output CHECKING SNUBBER CIRCUIT In case of an SCR malfunction or failure the snubber assembly should be checked Disconnect the input power to the CV 400 I at the fuse box and remove the right side of the machine 1 Visually inspect the snubber PC Board assembly located below the Control PC board on the case front for overheated components or damaged compo nents OPTIONAL K857 REMOTE CONTROL CHECK Disconnect the remote output control and connect an ohm meter between pins C and B and rotate the rheostat in the remote control The resistance reading should go from zero to 10K ohms Repeat with ohmmeter across A and B with the same results Connect ohmmeter across A and C The reading should be 10K ohms A lower reading will indicate a shorted or partially shorted rheostat A very high reading will indicate an open rheostat In either of the last two cases replace the rheostat CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN F 1 DIAGRAMS Jequunu epoo eu BAIN jueujeoe daoi 104 jueunjedeg BdIAIBS 01 1HA ejqiGej s eui j sjeued eunsoj oue y euo uo
50. ode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 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 pantalons sans revers et chaussures montantes LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch 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 debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 v v for selecting a QUALIT
51. ogs QN SIOUNOS d3MOd 1 A9 A9 NO 9351 LON _ 0 06 EN OVA SLL JN Qee gy OVA ZY o p 109100 ONIGTAM f o y 401 43H13901L LOANNOD 1 o o o ddvdS o 8 _ 18 UIYORW SIU Boles TIM NVO X90HS 91419373 SdNIHOVN TIV NO 1N3S38d LON MVaQ IN344n9 INQWIXVIN TWANVW NOILONGLSNI 394N0S d3MOd OL 43134 TN Y 8 SQV313S0 19 OL AV T3H NOILV1OSI 3SN LNdLNO ONIGTAM TVN 9IS V LVHL S430334 CN ATIVACIAIGNI QV31 CASANN H9V3 SLVINSNI 3ounos d3MOd LV 3 18VO ANY 3400419414 3543134 5330 H3MOd Nun ALlH v TOd 39NVHO OL gALLISOd 300810313 SMOHS INVHOVIO 8 N NOILVOlITddV 40 319A9 ALNG LN38Hf10 dOd Q3ZIS aq LSNW 318V9 ONITTAM V N o Gl gt TOULNOO LNAdLNO ALOWSY he 97 MOI 3ounos H1MOd 40 VNINHAL OL SLO3NNOO NOLLO3NNOO H313IALLTOA 430334 SHIM o 2 NOLLO3NNOO 3980008 HIMOd 20 039 719v9 3004191313 AYOM OL ON 1d YaldVdv TWSUAAINN 298 JON3HdIAV vl 10 esn ijejsui pjnous suosJed peijenb e au Bunoeuuoo e1ojeg esni au 1e U91IMS 12euuoosip 801n0S eu 01 indui e e ONINUYM Y JOENOS d3MOd I AO AO CV 400 I LINCOLN E F 5 F 5 DIAGRAMS CV POWER SOURCE TO A K86
52. onnect the J3 plug from the Control PC Board Measure the resistance between the following wire terminals in the plug A Between wire 200 and wire 201 B Between wire 202 and wire 203 Both of these resistances should be less than 1 ohm If these resistances are not less than 1 ohm check the wiring back to the main transformer If these voltages are less than 1 ohm refer to Procedure for Replacing PC Boards METER PC BOARD When the Meter PC Board malfunctions first determine if the rest of the machine functions correctly If so then the problem is in either the harness between the meter and control boards or in the meter board itself Refer to Procedure for Replacing PC Boards As a last resort the Control PC Board may have to be replaced CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed CV 400 I LINCOLN TROUBLESHOOTING 8 OUTPUT VOLTAGE The open circuit voltage of the machine should be 10 to 43 volts If any other condition exists refer to the Troubleshooting Guide FAULT PROTECTION OPERATION The overload protection circuit on the PC Board will cause the CV 400 I meter to display E60 This pro tection circuit will reset itself automatically The short circuit protection circuit will cause the meter t
53. ook Twelfth Edition 15 00 PH p How to Read Shop Drawings 5 H Video Information Incentive Management 5 00 IM lames F Lincoln Arc Welding Foundation Book Information Sraa la Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 A New Approach to Industria Economics 500 NA _ neAmercan Century of John C 55 00 ae Welding Preheat Calculator 3 00 wC8 FLF 518 Pipe Welding Chas 450 Ens l 1 UL CL LSUBTOTA ea Shipping Costs F l O Name Address Telephone Signature as it appears on Charge Card 5 L _ m men M WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e
54. rovides a means of connecting auxiliary equipment to the wire feeder receptacle on the CV 400 I power source Consists of a 14 pin MS type Amphenol plug with 8 inch 0 2 meter long flex leads one for each circuit present in the wire feeder receptacle Not required when using a standard wire feeder input cable such as a K480 with a Lincoln wire feeder COMPATIBLE LINCOLN EQUIPMENT The CV 400 I is intended for use with the LN 7 LN 742 and LN 25 wire feed units Use the Cables Kits listed below to make connection easily LN 7 LN 7GMA Requires K480 Input Cable LN 25 Requires K484 Jumper Plug Kit LN 25 w K444 1 Remote Voltage Control Kit Requires K864 Remote Control Adapter and K484 Jumper Plug Kit LN 742 LN 742H Requires K591 Input Cable European model CV 400 I does not provide 115 VAC auxiliary power for LN 7 models CV 400 I LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this maintenance Turn the input power OFF at the disconnect switch or fuse box before working on this equipment Do not touch electrically hot parts GENERAL MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot with prema ture tripping of thermal protection Blow out the welder with low pressure air at regu
55. servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD PRE RET BRAY FE BPTF e HMDS RK AGS XA Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE E U uA C F uv SHAE Ro e 20 Sel Sepe Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O it ie BIR Chinese Qai ge dul ale f cs jua jl sq Sarin e gad os uui ARI ge cal sd ue Ao pha J dust jui gail e Ads cuts Fi gall l Jai y e Ll gt LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K RA ETISRIUCESU CL TRHORERMEI HS F ux 85 ET REL BE PR Es Rr de OE D BB l fE SR 8
56. talled Options C 1 Compatible Lincoln Equipment eene nnns C 1 Maintenance ARKEEN AANEREN KAKEN RNE ESKENA KREEKA EEEREN Section D Safety Precautions u irt i id TE Eb ee ia D 1 General Maintenance nennen nennen nennen nnne trennt nnn nnne ens D 1 Machine and Circuit Protection D 1 Troubleshoeting IIIIIIIIIIIILN Section Safety Precautions iii E 1 How to Use Troubleshooting Guide E 1 Built in Diagnostic Routines and Error Codes Troubleshooting Guide E 2 Machine Troubleshooting Guide E 3 Options Troubleshooting Guide ss 6 Procedure for Replacing PC Boards E 7 Control and Meter PC Board Troubleshooting Procedures E 7 Output Voltage Fault Protection Snubber Circuit and K857 Remote Control Checks E 8 DIA QT AMS ieee Section F Parts Manwmal E Appendix A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS IDEALARC CV 400 I INPUT THREE PHASE ONLY Standard Input Current at Code Voltage Rated Output Number 220 380 440 3 50 60 10096 Duty Cycle 60 35 30 10183 Export NEMA Rated 6096 Duty Cycle 62 36 31 230 400 3 50 60 10096 Duty Cycle 58 34 10182 European IEC Rated 6096 Duty Cycle 60 33 380 500 3 50 60 100 Duty C
57. the old PC board to see if the problem still exists If it does no longer exist with old PC board 1 Check the PC board harness connector pins for corrosion contamination or looseness 2 Check leads in the plug harness for loose or intermittent connection b If PC board is visibly damaged electrically before possibly subjecting the new PC board to the same cause of failure check for possible shorts opens or grounds caused by 1 Frayed or pinched lead insulation 2 Poor lead termination such as a poor contact or a short to adjacent connection or surface 3 Shorted or open motor leads or other external leads 4 Foreign matter or interference behind the PC boards c If PC board is visibly damaged mechanically inspect for cause then remedy before installing a replacement PC board If there is damage to the PC board or if replacing PC board corrects problem return it to the local Lincoln Electric Field Service Shop PC BOARD TROUBLESHOOTING PROCEDURES CONTROL PC BOARD The Control PC Board controls all machine functions including the thermal protection indicator light and the Meter PC Board Most problems if not caused by faulty wiring machine misuse will stem from a faulty Control PC Board Perform the following diagnostic procedure before replacing the Control PC Board 1 Turn off the input power at the fuse box 2 Check for loose connections in the PC Board plugs particularly J3 3 Disc
58. ts the actual arc voltage may be lower than that displayed on the voltmeter Use welding cables of the proper capacity and make sure all connec tions are tight to minimize this effect F 42 VOLT CIRCUIT BREAKER Protects the 42 volt 41 42 circuit in the wire feeder receptacle from overloads and shorts If this circuit breaker opens the CV 400 I will work normally However any equipment powered by the 42 volt circuit will not work G 115 VOLT CIRCUIT BREAKER Protects the 115 volt 31 32 circuit in the wire feeder receptacle from overloads and shorts If this circuit breaker opens the CV 400 I will work normally However any equipment powered by the 115 volt circuit will not work H LOCAL REMOTE SWITCH Determines whether the welding voltage is controlled at the CV 400 I or controlled remotely by a remote output control such as K857 CV 400 I LINCOLN P B4 OPERATION B 4 J WIRE FEEDER VOLTMETER SWITCH When welding electrode negative most Innershield electrodes set the switch to This switch selects the polarity of the wire feeder voltmeter if so equipped When weld This switch has no effect on the welding ing electrode positive MIG Outershield and polarity In fact if the wire feeder being used some Innershield processes set the switch does not have a voltmeter the setting of this to switch has no effect GRAPHIC SYMBOLS THAT APPEAR ON THIS MACHINE OR IN THIS MANUAL THERMAL PROTE
59. u l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un 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 lev age 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 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 forte ment toxique ou autres produits irritants 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 jamais enrouler le c ble lectr
60. uipment 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 Also see item 1 b Mar 95 SAFETY 7 WELDING SPARKS can lt 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 249 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 steps 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 P
61. un to cool the power source No welding is possible until the machine is allowed to cool and the Thermostatic Protection Light goes out CV 400 I LINCOLN P C1 ACCESSORIES c1 FACTORY INSTALLED OPTIONS ACCESSORIES There are no factory installed options accessories on the CV 400 I FIELD INSTALLED OPTIONS REMOTE VOLTAGE CONTROL K857 The K857 consists of a control box with 25 feet 7 6 m of four conductor cable Installation of a K857 Remote Voltage Control in the CV 400 I requires a K864 Remote Control Adapter Refer to the instruc tions provided with the K857 for hookup to the CV 400 1 When properly connected and with the CV 400 1 Local Remote Switch in the Remote position the K857 functions the same as the CV 400 I Voltage Adjust control enabling minimum to maximum output voltage adjustment of the CV 400 I UNDERCARRIAGE K835 Includes front casters a handle a bracket and a rear wheeled platform that is capable of carrying one gas cylinder The CV 400 I lifting eye is not functional with the K835 undercarriage installed TWO CYLINDER UNDERCARRIAGE K874 Platform type undercarriage that can accommodate either one or two gas bottles or one gas bottle and a Magnum water cooler The CV 400 I lifting eye is not functional when the K874 undercarriage is installed WIRE FEEDER SWIVEL MOUNT K178 1 Allows an LN 7 or LN 742 to be securely mounted on the roof of a CV 400 I UNIVERSAL ADAPTER K867 P
62. ycle 35 26 10184 Export NEMA Rated 60 Duty Cycle 36 27 415 3 50 60 10096 Duty Cycle 32 10185 Export NEMA Rated 60 Duty Cycle 33 200 400 3 50 60 100 Duty Cycle 66 33 10186 Export NEMA Rated 6096 Duty Cycle 68 34 RATED OUTPUT Duty Cycle Volts at Rated Amperes NEMA Class II 60 36 100 Duty Cycle 32 IEC 974 1 60 34 100 Duty Cycle 29 OUTPUT Welding Current Voltage Range Normal Open Circuit Voltage Auxiliary Power Continuous 10 43 42 Volts AC 10 Amps 50A 7V 400A 37V MAX OCV 50 115 Volts AC 5 Amps Except Code 10182 DC 220 Volts AC 2 Amps Efficiency at 100 Load Input kVA All Circuit Breaker Protected NEMA Rated 78 IEC Rated 68 NEMA 60 Load 23 6 IEC 60 Load 23 2 NEMA 100 Load 22 9 IEC 100 Load 23 2 MISC INFORMATION Idle Power Power Factor at Rated Load Idle Current Amps 825W 80 16 9 8 Power Factor at 100 Load 55 PHYSICAL DIMENSIONS Width Weight 19 5 in Lift bail add 3 12 in 300 Ibs 137 kg 495 mm Lift bail add 80 mm CV 400 I LINCOLN A 2 Read entire installation section before starting installation SAFETY PRECAUTIONS A WARNING 9 ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Turn the input power OFF at the discon nect switch or fuse box before working on this equipment Turn the Power switch on the CV 400 I OFF before connecting or disconnect ing output cables wire fe

Lincoln Electric IDEALARC CV-400-I User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents