Lincoln Electric CV-400-I User Manual

IDEALARC CV-400-I

RETURN TO MAIN MENU

For use with machine Code Numbers 10182, 10183,10084, 10085 & 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 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.

IM501-A

June, 2002

CV-400-I

OPERATOR’S MANUAL

• 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

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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 purchase a copy of “Safety in Welding & 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.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance 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.

____________________________________________________

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 vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

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.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

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.

___________________________________________________

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 running.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

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

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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.

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.

___________________________________________________

1.g. 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.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

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.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

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. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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.

3.f.

Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the

material safety data sheet (MSDS) and follow your

employer’s safety practices. MSDS forms are available from

your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

vapors

iii

SAFETY

iii

WELDING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. 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.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. 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 been “cleaned”. For information, purchase “Recommended Safe Practices for the Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

6.g. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. 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.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Mar ‘95

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés 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 couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• 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 & Number _____________________________________

Code & 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:

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

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

Select Suitable Location ........................................................................................A-2

Input Connections..................................................................................................A-2

Field Installed Options ...........................................................................................A-3

Required Equipment - Control Cable Connections................................................A-3

Output Connections...............................................................................................A-3

Paralleling .............................................................................................................A-4

Connection of Auxiliary Equipment to Wire Feeder Receptacle............................A-4

Operation .........................................................................................................Section B

Safety Precautions ................................................................................................B-1

General Description...............................................................................................B-2

Recommended Processes and Equipment ...........................................................B-2

Operational Features and Controls........................................................................B-2

Design Features ....................................................................................................B-2

Limitations..............................................................................................................B-2

Power Source Operation .......................................................................................B-2

Duty Cycle .............................................................................................................B-2

Controls and Settings ............................................................................................B-3

Graphic Symbols ...................................................................................................B-4

Output Panel Connections.....................................................................................B-5

Case Back Connections ........................................................................................B-6

Starting the Machine..............................................................................................B-7

Adjusting the Output Voltage using the Digital Meter ............................................B-7

Local/Remote Switch Operation ............................................................................B-7

Auxiliary Power......................................................................................................B-7

Overload Protection...............................................................................................B-7

Accessories.....................................................................................................Section C

Factory/Field Installed Options..............................................................................C-1

Compatible Lincoln Equipment..............................................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

General Maintenance ............................................................................................D-1

Machine and Circuit Protection..............................................................................D-1

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................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............................................................................E-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

Diagrams ..........................................................................................................Section F

Parts Manual....................................................................................................Appendix

....................E-8

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC CV-400-I

INPUT - THREE PHASE ONLY

Standard

Voltage

220/380/440/3/50/60

Input Current at

Rated Output

100% Duty Cycle 60/35/30

60% Duty Cycle 62/36/31

A-1

Code

Number

10183 (Export, NEMA Rated)

230/400/3/50/60

380/500/3/50/60

415/3/50/60

200/400/3/50/60

Duty Cycle

NEMA Class II (60)

100% Duty Cycle

IEC 974-1 60%

100% Duty Cycle

Welding Current/Voltage Range

(Continuous)

50A/7V - 400A/37V

Efficiency at 100% Load

NEMA Rated 78%, IEC Rated 68%

100% Duty Cycle 58/34

60% Duty Cycle 60/33

100% Duty Cycle 35/26

60% Duty Cycle 36/27

100% Duty Cycle 32

60% Duty Cycle 33

100% Duty Cycle 66/33

60% Duty Cycle 68/34

10182 (European, IEC Rated)

10184 (Export, NEMA Rated)

10185 (Export, NEMA Rated)

10186 (Export, NEMA Rated)

RATED OUTPUT

Amps

400 300

Volts at Rated Amperes

OUTPUT

Normal Open Circuit Voltage

10-43

MAX OCV: 50

Input kVA

NEMA 60% Load - 23.6, IEC 60% Load - 23.2

NEMA 100% Load - 22.9, IEC 100% Load - 23.2

Auxiliary

42 Volts AC, 10 Amps

115 Volts AC, 5 Amps (Except Code 10182)

220 Volts AC, 2 Amps

( All Circuit Breaker Protected)

36 32

34 29

Power

MISC. INFORMATION

Idle Power

825W

Power Factor at Rated Load

.80

Power Factor at 100% Load

.55

Idle Current - Amps

16/9/8

PHYSICAL DIMENSIONS

Height Width Depth Weight

21.5 in. 19.5 in. 27.0 in. (Lift bail, add 3.12 in) 300 lbs

(137 kg)

546 mm 495 mm 686 mm

(Lift bail, add 80 mm)

CV-400-I

A-2

INSTALLATION

A-2

Read entire installation section before starting installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should perform this installation.

• Turn the input power OFF at the disconnect switch or fuse box before working on this equipment.

• Turn the Power switch on the CV-400-I “OFF” before connecting or disconnecting output cables, wire feeder 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 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.

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.

TILTING

Do not place the machine on a surface that is inclined enough to create a risk of the machine falling over.

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 L1, L2, and L3 of the input reconnect panel in accordance 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" fuses. Using fuses or circuit breakers smaller than recommended may result in "nuisance" tripping from welder inrush currents even if not welding at high currents.

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

Frequency

208/60

230/60

460/60

575/60

200/50/60

220/50/60

230/50/60

380/50/60

400/50/60

415/50/60

440/50/60

500/50/60

circuit breakers may be used in place of

Fuse

(Super Lag)

or Breaker

Size

100

Input

Ampere

Rating on

Nameplate

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes

4 (25 mm2)

10 (6mm2)

4 (25 mm2)

8 (10mm2)

10 (6mm2)

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

8 (10mm2)

10 (6mm2)

8 (10mm2)

10 (6mm2)

CV-400-I

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit breakers which have a delay in tripping action that decreases as the magnitude of the current increases.

A-3

INSTALLATION

A-3

FIELD INSTALLED OPTIONS

For installation of compatible field installed options (see the ACCESSORIES section of this manual 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.

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 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 "

") or the high inductance terminal (marked

" ").

TABLE A.1

Cable Sizes for Combined Lengths of Copper

Electrode and Work Cable

Machine Size

300 A 100% (400 A 60%)

Lengths up to

150 ft 150 to 200 ft

2/0 (70mm2) 3/0 (95mm

)

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.

CV-400-I

A-4

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 receptacle. 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 convenience, wire feeder connection details are shown in the DIAGRAM section.

A-4

NOTE: If you intend to use a standard Lincoln wire

feeder, order the appropriate input cable for the specific feeder. It will make all of the control and power connections between the CV400-I and the wire feeder WITHOUT the need for a K867 Universal Adapter.

CV-400-I

B-1

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section before operating the machine.

GENERAL WARNINGS

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground.

B-1

• 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

B-2

OPERATION

• Circuit breaker protected.

CAUTION

• 115 VAC, 5 amp auxiliary power available for the wire

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 several seconds.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The CV 400-I is a constant voltage DC power source designed for the GMAW process with limited FCAW capability 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-I features an all graphic nameplate and has an IEC 974-1 S Rating for use in environments with an increased hazard of electric shock.

feeder; circuit breaker protected. (Except Code 10182).

• 220 VAC, 2 amp Auxiliary power available for water coolers, 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 protection against moisture and corrosive atmospheres.

• Microprocessor based Control PC Board has built-in diagnostic routines.

RECOMMENDED PROCESSES AND EQUIPMENT

• Compact size, requires only 19" x 26" footprint.

B-2

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 auxiliary power for the LN-7 models.

OPERATIONAL FEATURES AND

• 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 following FCAW electrodes: NR-152, NR-211, NR-203 Ni 1%, NS-3M, Outershield 70 and 71. The machine has been designed primarily for the GMAW process.

CONTROLS

POWER SOURCE OPERATION

• Two inductance positions: operator can choose the optimum output characteristics.

• Solid State Output Contactor: no noise, no moving parts to wear.

Be sure the CV-400-I is properly installed, and that all accessories are properly hooked up before attempting operation.

DUTY CYCLE

• Digital Voltmeter/Ammeter is standard.

• Power on/off switch.

Duty Cycle is based on operation for a 10 minute period.

• 42 VAC, 10 amp auxiliary power available for the wire feeder.

300 Amps, 32 Volts at 100% 400 Amps, 36 Volts at 60%

CV-400-I

B-3

OPERATION

B-3

CONTROLS AND SETTINGS

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

A. POWER SWITCH F. 42 VOLT CIRCUIT BREAKER B. VOLTAGE ADJUSTMENT G. 115 VOLT CIRCUIT BREAKER C. THERMAL PROTECTION INDICATION LIGHT H. LOCAL / REMOTE SWITCH D. VOLTS / AMPS SWITCH J. WIRE FEEDER VOLTMETER 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-

D. VOLTS/AMPS SWITCH

tion will result in the most rapid cooling.

- Selects either output current or arc voltage to be displayed on the digital meter.

NOTE: Due to voltage drops in the welding cables

and at cable connection points, the actual arc voltage may be lower than that displayed on the voltmeter. Use welding cables of the proper capacity and make sure all connections 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

E. DIGITAL VOLTMETER/AMMETER

- Displays the CV-400-I output current, or the arc voltage.

CV-400-I

-Determines whether the welding voltage is controlled at the CV-400-I, or controlled remotely by a remote output control (such as a K857).

B-4

OPERATION

B-4

J. WIRE FEEDER VOLTMETER SWITCH

-This switch selects the polarity of the wire feeder voltmeter, if so equipped. When welding electrode positive (MIG, Outershield and some Innershield processes) set the switch to "+".

GRAPHIC SYMBOLS THAT APPEAR ON

THIS MACHINE OR IN THIS MANUAL

-When welding electrode negative (most Innershield electrodes) set the switch to "-".

-This switch has no effect on the welding polarity. In fact, if the wire feeder being used does not have a voltmeter, the setting of this switch has no effect.

THERMAL PROTEC-

OFF

POWER

AC AUXILIARY

POWER

REMOTE OUTPUT

VOLTAGE CONTROL

TION INDICATOR

LIGHT

CIRCUIT

BREAKER

CLOCKWISE ROTA-

TION INCREASES

VOLTAGE

INPUT

LOCAL OUTPUT

VOLTAGE CONTROL

WARNING

INDICATES WARNING INFORMATION

LOCATED ON RIGHT CASE SIDE

CV-400-I

B-5

OPERATION

OUTPUT PANEL CONNECTIONS

FIGURE B.2 - OUTPUT PANEL

A. POSITIVE OUTPUT CONNECTION C. HIGH INDUCTANCE NEG. CONNECTION B. LOW INDUCTANCE NEG. CONNECTION D. WIRE FEEDER RECEPTACLE

B-5

A., B., C. 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, particularly on thin materials or when using CO

shielding gas.

C. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION.

-The high inductance connection is more suitable for short arc welding heavier weldments or when using 75% Argon/25% CO2shield-

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.

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.

CV-400-I

B-6

CASE BACK CONNECTIONS

OPERATION

FIGURE B.3 - BACK PANEL

B-6

A. 220 VAC RECEPTACLE C. CABLE CLAMP FOR INPUT CABLES B. CIRCUIT BREAKER

A. 220 VAC RECEPTACLE

Continental European type, nonpolarized, grounded receptacle (also known as a "Schuko" type) for connection of water coolers or other equipment.

B. CIRCUIT BREAKER

Protects the 220 volt auxiliary circuit from over-

loads and shorts. If this breaker opens, the CV 400-I will work normally; however, equipment powered by the 220 volt receptacle will not work.

C. CABLE CLAMP FOR INPUT CABLES

CV-400-I

B-7

OPERATION

B-7

STARTING THE MACHINE

The power switch at the extreme right side of the control 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 preset 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 welding voltage. (See below if an external power source remote control is installed.)

When an arc is struck, the digital meter displays the actual welding voltage, as measured at the CV-400-I output terminals.

NOTE: The arc voltage at the electrode may be as much as

two volts different from the CV-400-I 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 adequate 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 INSTALLATION section), place the Local/Remote switch (see Figure B.1) in the "Remote" position. The remote control now controls 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 wire feeder receptacle. A 10 amp circuit breaker protects the 42 volt circuit from overloads.

CV-400-I Export machines only can also supply 115 volt AC auxiliary power through the wire feeder receptacle. 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 receptacle, 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 equipment.

___________________________________________

OVERLOAD PROTECTION

This welder has thermostatic protection from excessive 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 illumination of the yellow Thermostatic Protection Light on the case front (see Figure B.1).The fan will continue to run 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

C-1

ACCESSORIES

C-1

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 instructions provided with the K857 for hookup to the CV400-I. When properly connected, and with the CV400-I 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)

COMPATIBLE LINCOLN EQUIPMENT

The CV-400-I is intended for use with the LN-7, LN742, 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

LN-25 w/K444-1 Requires K864 Remote Control Remote Voltage Adapter and K484 Jumper Plug Control Kit 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.

Requires K484 Jumper Plug Kit

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)

Provides 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.

CV-400-I

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 premature tripping of thermal protection. Blow out the welder with low pressure air at regular intervals to eliminate excessive dirt and dust build-up on internal 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 TROUBLESHOOTING 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 protection 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 overloads and accidental short circuits. The overload protection 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 CV400-I 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

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by 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 problems 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 possible 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 categories: output problems, function problems, welding problems.

E-1

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 without removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS.

If you have exhausted all of the recommended 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, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

_____________________________________________________________________

CV-400-I

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

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, trouble conditions, and possible remedies are listed below.

ERROR

CODE

E00

E10

E20

E30

E40

E50

TROUBLE REMEDY

1. Output short circuited.

2. May be encountered while starting or welding with 1/16" aluminum wire.

Thermostat circuit has opened.

Memory error.

1. Voltage Adjust potentiometer not connected.

2. Remote Control not functioning correctly.

Input line voltage too low.

Input line voltage too high.

1. Turn power off. Remove short circuit.

2. a) Turn power off to clear error. Use recommended wfs, voltage settings and angle of approach of wire to work.

b) If problem still persists, call Local Lincoln

Authorized Field Service Facility.

Allow machine to cool. Be sure to provide adequate ventilation for machine.

See PC Board Troubleshooting Procedure.

1. Check wiring between Voltage Adjust and the

Control PC Board.

2. See Options Troubleshooting Guide.

Turn power off. Insure machine input voltage is within specifications. Turn power back on.

E60

If, after attempting the remedies 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).

Overload condition.

Reduce load on machine.

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

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

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)

Machine has no output.

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

PROBLEMS

1. Secondary contactor circuit (2 and 4 wire feeder receptacle) not working.

2. Electrode or work lead loose or broken.

3. Defective PC Board.

4. Protective circuits operating due to output short circuit.

5. If using an LN-25, K484 jumper plug kit not making connection between 2 & 4 in wire feeder receptacle.

6. If welding with 1/16" aluminum wire and machine is flashing E00.

RECOMMENDED

COURSE OF ACTION

1. Check 2 and 4 circuit wiring.

2. Repair connection.

3. See PC Board Troubleshooting Procedure.

4. Turn power off. Remove output short circuit.

5. Check for continuity between pins C & D in the K484.

6. a) Turn power off to clear error. Use

recommended wfs, voltage settings and angle of approach of wire to work.

b) If problem still persists, call Local Lincoln

Authorized Field Service Facility.

Machine has minimum output and no control.

Machine has low output and no control.

1. Voltage Control misconnected.

1. Open in feedback circuitry.

2. Faulty PC Board.

3. Voltage Adjust potentiometer circuit open (lead 75).

1. Voltage Control wiring.

1. Check wiring and control and PC board wiring harness plugs.

2. See PC Board Troubleshooting Procedure.

3. Check and replace potentiometer if faulty. Check wiring of lead #75.

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

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Thermal Protection Indicator light is on.

Machine does not have maximum output

Machine will not shut off.

Variable or sluggish welding arc.

POSSIBLE AREAS OF MISADJUSTMENTS(S)

PROBLEMS

1. Thermostat circuit has opened.

2. Faulty Control PC Board.

1. Faulty Control PC Board.

2. Voltage Adjust potentiometer defective.

3. Voltage Adjust potentiometer leads open.

1. Defective power switch.

1. Poor work or electrode connection.

RECOMMENDED

COURSE OF ACTION

1. Allow machine to cool. Be sure to provide adequate ventilation for machine.

2. See PC Board Troubleshooting Procedure.

1. See PC Board Troubleshooting Procedure.

2. Check and replace if faulty.

3. Check and repair broken leads.

1. Replace.

1. Check and clean all connections.

Digital meters do not light

- or -

Digital meter display is incorrect.

2. Welding leads too small.

3. Welding current or voltage too low.

4. Defective SCR bridge.

1. Faulty Meter PC board.

2. Faulty Control PC Board.

2. Check table in this manual.

3. Check procedures for recommended settings.

4. Check and replace if defective.

1. See PC Board Troubleshooting Procedure.

2. 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

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

(SYMPTOMS)

Output Control not functioning on the machine.

Poor arc striking with semiautomatic wire feeders.

POSSIBLE AREAS OF MISADJUSTMENTS(S)

PROBLEMS

1. Local/Remote switch is in the "Remote" position.

2. Faulty Voltage Adjust potentiometer.

3. Leads or connections open in control circuit.

4. Malfunctioning Remote Control.

5. Faulty Control PC board.

1. Poor work connection.

2. Improper procedures.

3. Wire feed acceleration too fast or too slow.

RECOMMENDED

COURSE OF ACTION

1. Move switch toggle to the "Local" position.

2. Check and replace if found faulty.

3. Check lead continuity and connections for an open and repair if necessary.

4. See "Options Troubleshooting".

5. See PC Board Troubleshooting Procedure.

1. Work connection must be adequate for application.

2. Adjust procedures for improved starting.

3. Adjust wire feeder acceleration setting, if provided.

Poor arc characteristics

4. Defective PC Board.

1. Control PC Board defective.

4. See PC Board Troubleshooting Procedure.

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

E-6

Observe all Safety Guidelines detailed throughout this manual

TROUBLESHOOTING

OPTIONS TROUBLESHOOTING GUIDE

K857 (or other) Remote Output Control

E-6

PROBLEMS

(SYMPTOMS)

Output control not functioning on Remote Control.

Voltage Adjust not functioning on the machine.

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

PROBLEMS

1. Local/Remote switch in wrong position.

2. Faulty Local/Remote switch.

3. Faulty Remote Control potentiometer.

4. Leads or connections open in control circuit.

5. Faulty Control PC board.

1. Local/Remote switch in the wrong position.

2. Faulty Local/Remote switch.

RECOMMENDED

COURSE OF ACTION

1. Place switch in "Remote".

2. Check and replace if found faulty.

3. Check and replace if found faulty.

4. Check all leads and connections, internal or remote, for continuity; repair if necessary.

5. See PC Board Troubleshooting Procedure.

1. Place switch in "Local" position.

2. Check and replace if found faulty.

3. Faulty Voltage Adjust potentiometer.

3. 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

E-7

TROUBLESHOOTING

E-7

Procedure for Replacing PC Boards

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified individual install and service this equipment.

• Turn the power source input power off at the disconnect switch before working 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 question for any electrical or mechanical damage to any of its components and conductors on the back of the board.

a. If there is no

install a new one and see if this remedies the problem. If the problem is remedied, reinstall 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.

visible damage to the PC board,

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. Disconnect 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.

2. Check leads in the plug harness for loose or intermittent connection.

b. If PC board is visibly damaged electrically

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.

, before

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

E-8

TROUBLESHOOTING

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 protection circuit will reset itself automatically. The short circuit protection circuit will cause the meter to 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.

E-8

1.Visually inspect the snubber PC Board assembly (located below the Control PC board on the case front for overheated components or damaged components).

OPTIONAL K857 REMOTE CONTROL CHECK

Disconnect the remote output control and connect an ohmmeter 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

F-1

213

P.C. BOARD

823

SNUBBER/BYPASS

221

224

223

222

204C

7.5 OHM

220 W

204D

SCR3

223

213

SHUNT

400 A. 50mV

214

224A

213A

SCR2

213B

6-18-93

L8928

F-1

DIAGRAMS

115 VAC

42 VAC

VOLTMETER

WIRE FEEDER

214A

WIRE FEEDER

VOLTMETER

SWITCH

213A

214

214B

224B

204D

204C

SCR1

LOCAL/REMOTE SWITCH

219

204A

L1 CHOKE

218

213B

222

376

377

277

J10

P. C. BOARD

221

276

224B

224

(SHOWN IN LOCAL POSITION)

CONTROL

224A

377

376

10K

214B

224B

204A

OUTPUT

CONTROL

N.A.

276

277

738

203

213B

202

O2 TOP

12V

242

207

275

215

201

200

SECONDARY

THERMOSTAT

41A

O1 TOP

12V

208

205

O1 TOP

42V

206

METER

209

42A

GROUND

P.C.

BOARD

210

211

212

10A

CIRCUIT

BREAKER

CB1

CUSTOMER

CONNECTIONS

WIRE

FEEDER

RECEPTACLE

N.A.

VOLTS / AMPS

(SHOWN IN "VOLTS" POSITION)

ELECTRICAL SYMBOLS

PER E1537

CIRCUIT

BREAKER

CB2

115V

FAN

33A

O3 TOP

58V

O3 BOT.

58V

10 PIN

8 PIN

6 PIN

4 PIN

(COMPONENT SIDE OF P. C. BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

31B

31A

C1-C4 31,000 MFD EACH

2 PIN

J10

N.C. TAP LEADS D, E, AND F APPEAR ON THE BOTTOM PRIMARY COILS

N.A. WIRING VIEWED FROM REAR OF POTENTIOMETER

N.B. THIS PERMANENT CONNECTION IS MADE AT THE MAIN TRANSFORMER

FOR 415V, 200/400V, AND 380/500V MACHINES ONLY.

BREAKER

CIRCUIT

CB3

220V

52A

O2 BOT.

127V

O1 BOT.

127V

OF 380/500V MACHINES ONLY.

LINES

N.B.

L1 L3

RECONNECT

PANEL

INPUT SUPPLY

WIRING DIAGRAM CV 400-I (EXPORT)

LINE

SWITCH

174

N.C.

440V

RECONNECT

PANEL

380V

* TO A SYSTEM GROUND PER

NATIONAL ELECTRICAL CODE.

RECONNECT

PANEL

220/380/440 INPUT VOLTAGES

220V

RECONNECT

PANEL

1110 12

2 3 1

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

CV-400-I

500V380V415V

RECONNECT

PANEL

RECONNECT

PANEL

RECONNECT

PANEL

380/500 INPUT VOLTAGES

415 INPUT VOLTAGE

2 3 1

TO S1 LINE SWITCH

RECONNECT

231 231

2 3 1

200/400 INPUT VOLTAGES

TO S1 LINE SWITCH

RECONNECT

2 3 1

TO S1 LINE SWITCH

200V 400V

PANEL

231 231

2 3 1

MAIN TRANSFORMER

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

F-2

DIAGRAMS

F-2

3-10-95H

L9857

213

P.C. BOARD

823

SNUBBER/BYPASS

221

224

223

222

204C

7.5 OHM

220 W

204D

SCR3

223

213

SHUNT

400 A. 50mV

214

224A

213A

SCR2

213B

FEEDER

VOLTMETER

WIRE

377

214B

204A

224B

242

377

376

10K

OUTPUT

CONTROL

N.A.

275

276

277

738

213B

201

203

200

202

O1 TOP

O2 TOP

12V

214A

WIRE FEEDER

VOLTMETER

SWITCH

213A

214

214B

L1 CHOKE

218

213B

222

219

224B

204A

204C

204D

SCR1

376

J10

P. C. BOARD

221

224B

224

276

277

(SHOWN IN LOCAL POSITION)

LOCAL/REMOTE SWITCH

CONTROL

224A

207

215

SECONDARY

THERMOSTAT

41A

208

205

206

O1 TOP

42V

METER

209

42A

42 VAC

P.C.

210

10A

CB1

GROUND

WIRE

BOARD

N.A.

VOLTS / AMPS

211

212

(SHOWN IN "VOLTS" POSITION)

CIRCUIT

BREAKER

O3 TOP

58V

CUSTOMER

FEEDER

RECEPTACLE

ELECTRICAL SYMBOLS

33A

CONNECTIONS

10 PIN

8 PIN

6 PIN

4 PIN

2 PIN

220V

O2 BOT.

127V

J10

C1-C4 31,000 MFD EACH

N.A. WIRING VIEWED FROM REAR OF POTENTIOMETER

CIRCUIT

BREAKER

CB3

O1 BOT.

127V

(COMPONENT SIDE OF P. C. BOARD)

CONNECTOR CAVITY NUMBERING SEQUENCE

PER E1537

FAN

31A

52A

O3 BOT.

58V

RECONNECT

PANEL

WIRING DIAGRAM CV 400-I (EUROPE)

INPUT SUPPLY

LINES

L1 L3

LINE

SWITCH

174

* TO A SYSTEM GROUND PER

NATIONAL ELECTRICAL CODE.

400V

RECONNECT

PANEL

230V

230/400 INPUT VOLTAGES

RECONNECT

PANEL

CV-400-I

MAIN TRANSFORMER

1110 12

2 3 1

TO S1 LINE SWITCH

2 3 1

TO S1 LINE SWITCH

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

F-3

DIAGRAMS

CV POWER SOURCE TO AN LN-7 AND K857

LN-7/LN-7GMA

WIRE

FEEDER

F-3

6-18-93

ASSEMBLY

K480 INPUT CABLE

S20662

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

14 PIN

AMPHENOL

SHOCK

ELECTRIC

WARNING

CAN KILL

CV/CV-I

OPTIONAL K857

REMOTE CONTROL

N.C.

POWER SOURCE

CONTROL ADAPTER

OPTIONAL K864 REMOTE

ELECTRODE CABLE

TO WORK

CV-400-I

CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE.

N.C. USE OF THE K857 REMOTE CONTROL REQUIRES THE INSTALLATION OF A K864 REMOTE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

F-4

DIAGRAMS

CV POWER SOURCE TO AK867 UNIVERSAL ADAPTER

N.F.

N.C.

N.D.

N.F.

N.E.

REMOTE OUTPUT CONTROL

{

WIRE

FEEDER

K867

6-18-93

S20658

F-4

CONNECT TOGETHER FOR

NOT USED ON CV/CV-I POWER SOURCES

SPARE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

WELDING OUTPUT

42 VAC

115 VAC

WIRE FEEDER VOLTMETER CONNECTION

POWER SOURCE FRAME CONNECTION

GND

AMPHENOL

K867 UNIVERSAL

ADAPTER PLUG

MIN.

10K

CONNECTS TO (WORK TERMINAL) OF POWER SOURCE

CV/CV-I

POWER SOURCE

CV-400-I

ELECTRODE CABLE

TO WORK

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

CURRENT DRAW.

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.

RELAY TO CLOSE LEADS 2 & 4.

N.F. NOT PRESENT ON ALL MACHINES

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION

F-5

DIAGRAMS

CV POWER SOURCE TO AK867 / K775 / LN-7

LN-7

WIRE

FEEDER

K291 OR K404

INPUT CABLE

K775 OPTIONAL

F-5

6-18-93

S20659

REMOTE CONTROL

N.C.

828142

SPARE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

GREEN

GND

757677

N.D.

GND

757677

14 PIN

AMPHENOL

CV/CV-I

POWER SOURCE

CV-400-I

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE

TO WORK

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.D. SPLICE LEADS AND INSULATE.

F-6

DIAGRAMS

CV POWER SOURCE TO AN LN-25

LN-25

WIRE FEEDER

REMOTE CONTROL

OPTIONAL K857

F-6

6-18-93

S20661

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

ELECTRIC

WARNING

CAN KILL

14 PIN

AMPHENOL

CV/CV-I

POWER SOURCE

N.C.

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

CONTROL ADAPTER

OPTIONAL K864 REMOTE

ELECTRODE CABLE

OPTIONAL

N.D.N.D.

K484 JUMPER

PLUG

TO WORK

CV-400-I

CONTROL ADAPTER TO THE 14 PIN AMPHENOL OF THE POWER SOURCE.

IF USING A K857 REMOTE CONTROL,CONNECT THE K484 JUMPER PLUG

OF THE POWER SOURCE IF NO REMOTE CONTROL IS USED.

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE.

N.C. USE OF THE K857 REMOTE CONTROL REQUIRES INSTALLATION OF A K864 REMOTE

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.D. CONNECT THE K484 JUMPER PLUG DIRECTLY TO THE 14 PIN AMPHENOL

TO THE 14 PIN AMPHENOL OF THE K864 REMOTE CONTROL ADAPTER.

THE POWER SOURCE WELDING TERMINALS ARE ALWAYS "HOT" WHEN THE K484 JUMPER

F-7

DIAGRAMS

CV POWER SOURCE TO AN LN-25 / K444-1

LN-25

WITH K444-1 OPTION

WIRE FEEDER

F-7

6-18-93

S20663

CONTROL ADAPTER

OPTIONAL K864 REMOTE

service this machine.

Only qualified persons should install, use or

Before connecting the wire feeder.

using the disconnect switch at the fuse box

Turn off input power to the Welding Power Source

SHOCK

WARNING

ELECTRIC

CAN KILL

14 PIN

AMPHENOL

CV/CV-I

POWER SOURCE

N.D.N.D.

OPTIONAL

K484 JUMPER

PLUG

ELECTRODE CABLE

N.C.

TO WORK

K864 REMOTE CONTROL ADAPTER. CONNECT THE 6 PIN PLUG FROM THE

LN-25 (WITH K444-1 OPTION) TO THE 6 PIN RECEPTACLE OF THE K864

CV/CV-I POWER SOURCE TO LN-25 WITH K444-1 OPTION CONNECTION DIAGRAM

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.C. CONNECT THE K484 JUMPER PLUG TO THE 14 PIN RECEPTACLE OF THE

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE, SWITCH LN-25 POLARITY SWITCH.

PLUG KIT IS INSTALLED.

REMOTE CONTROL ADAPTER. SWITCH THE POWER SOURCE "LOCAL/REMOTE" SWITCH TO REMOTE.

N.D. THE POWER SOURCE TERMINALS ARE ALWAYS "HOT" WHEN THE K484 JUMPER

CV-400-I

F-8

DIAGRAMS

LINCOLN POWER SOURCE TO AN LN-742

K=42

C=2

S20409

1-28-94

D=4

F-8

E=77

service this machine.

Only qualified persons should install, use or

Power Source before connecting the wire feeder.

Turn off (0) the power switch on the Welding

SHOCK

ELECTRIC

WARNING

CAN KILL

LN-742

WIRE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT

AND DUTY CYCLE OF APPLICATION.

FEEDER

N.D.

14 PIN

AMPHENOL

I=41

H=21

N.B. DIAGRAM SHOWS ELECTRODE POSITIVE. TO

CHANGE POLARITY, TURN POWER "OFF",

REVERSE ELECTRODE AND WORK CABLES AT

POWER SOURCE AND SET WIRE FEEDER

VOLTMETER POLARITY SWITCH ON POWER

SOURCE TO PROPER POLARITY.

LN-742

N.D. IF USING K589-1, REMOTE CONTROL KIT,

SET POWER SOURCE CONTROL SWITCH

N.C. PINS NOT LISTED ARE NOT CONNECTED

ON CABLE.

INPUT CABLE

ASSEMBLY

TO "REMOTE" POSITION.

K=42

I=41

H=21

C=2

G=75

D=4

F=76

14-SOCKET BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

F=76

E=77

14-SOCKET BOX RECEPTACLE, FRONT VIEW

AND 14-PIN CABLE PLUG, REAR VIEW

LINCOLN

POWER SOURCE

ELECTRODE CABLE

TO WORK

CV-400-I

WORK

42V AC

FUNCTION

TRIGGER CIRCUIT

LEAD

FUNCTIONS ARE LISTED FOR REFERENCE

(SEE APPROPRIATE WIRING DIAGRAM)

ONLY AND EACH MAY OR MAY NOT BE

PRESENT IN YOUR EQUIPMENT.

OUTPUT CONTROL

F-9

DIAGRAMS

K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS

F-9

K=42

J=31

A=32

J=31

B=GND

I=41

C=2

H=21

N=SPARE

H=21

L=82

D=4

G=75

N=SPARE

G=75

E=77

F=76

S19386

3-16-90

M=81

14-PIN BOX RECEPTACLE, REAR VIEW

AND 14-PIN CABLE PLUG, FRONT VIEW

K=42

A=32

L=82

B=GND

D=4

C=2

INSTALLATION INSTRUCTIONS

MAY OR MAY NOT BE ISOLATED, INDEPENDENT CIRCUITS INSIDE THE WELDER.

TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE.

WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS

THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN

THIS ADAPTER TO WIRE FEEDER CABLE.

1. TURN THE POWER SWITCH OF THE WELDING POWER SOURCE OFF BEFORE INSTALLING

CONSULT THE WIRING DIAGRAM OF THE POWER SOURCE AND WIRE FEEDER THIS ADAPTER WILL BE USED WITH.

NOTE: 115V AC (31, 32), 42V AC (41, 42), 24V AC (SPARE) AND TRIGGER CIRCUIT (2, 4)

THE STANDARD CONNECTOR PIN DESIGNATIONS AND FUNCTIONS ARE SHOWN BELOW.

2. CONSULT THE APPROPRIATE EQUIPMENT WIRING DIAGRAMS FOR THE CONNECTIONS TO UNIVERSAL ADAPTER.

IN THE UNIVERSAL ADAPTER. THE INSULATING METHOD MUST BE RATED FOR 120V AC OR GREATER.

3. USE LUG, CRIMP SPLICE OR SOLDER CONNECTIONS AS REQUIRED AND INSULATE EACH USED AND UNUSED LEAD STANDARD FUNCTION

115V AC

CHASSIS CONNECTION

TRIGGER CIRCUIT

OUTPUT CONTROL

TRIGGER CIRCUIT

OUTPUT CONTROL

M=81

E=77

14-PIN BOX RECEPTACLE, FRONT VIEW

WORK

115V AC

42V AC

OUTPUT CONTROL

AND 14-PIN CABLE PLUG, REAR VIEW

24V AC

WELDING MODE CONTROL

42V AC

WELDING MODE CONTROL

GND

NOT ALL CIRCUITS ARE PRESENT IN EVERY POWER SOURCE, NOR ARE THEY REQUIRED FOR PROPER WIRE FEEDER OPERATION.

(SEE APPROPRIATE WIRING DIAGRAM)

THESE FUNCTIONS ARE LISTED FOR

LEAD

REFERENCE ONLY AND EACH MAY OR

MAY NOT BE PRESENT IN YOUR EQUIPMENT.

SPARE

CV-400-I

F-10

DIAGRAMS

TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS

TWIST-MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS

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.

CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE

1. APPROPRIATE CABLE SIZE PER TABLE BELOW; AND

SKIN CABLE JACKET TO LENGTH SPECIFIED:

F-10

BOOT MARKING

35-50

50-70

70-95

If necessary, trim cable end of boot at groove(s) to match cable

2. 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.

WELDING CABLE

Slide the copper tube into the brass plug.

Insert cable into copper tube.

AMERICAN (EUROPEAN) RANGE

#2-#1

1/0-2/0

2/0-3/0

SEE

ABOVE

CABLE SIZE

(

35-50

(

50-70

70-95

(

mm )

TRIM

CABLE SKIN LENGTH

1 INCH (25.4mm)

1.5 INCH (38.1mm)

BOOT

SET SCREW (70-95 size may

have 2 set

screws)

COPPER TUBE

Tighten set screw(s) to collapse copper tube. Screw(s)

6. must apply firm pressure against welding cable. The top of the

set screw(s) will be nearly flush or below the surface of the

brass plug after tightening.

Slide rubber boot over brass plug. The rubber boot must be

7. positioned to completely cover all electrical surfaces after

the plug is locked into the receptacle.

CV-400-I

BRASS PLUG

9-20-91J

S18737

F-11

DIAGRAMS

CONNECTION OF NON-LINCOLN WIRE FEEDERS

F-11

CV-400-I

F-12

3.90 (99)

11.99 (304)

41.58 (1056)

.28

(7.0)

12.60 (320)

DIAGRAMS

DIMENSION PRINT

N.A.

1.00 (25.4)

23.62 (600)

F-12

M15665

5-18-90J

WELDER DOWN USING 5/16 SCREWS

26.00 (660)

3.61 (91)

1.68 (42.7)

N.B.

24.75

(628)

21.50 (546)

30.95

(786)

N.A.

6.20 (157)

N.B. HANDLE CONFIGURATION ON EARLIER MODELS.

N.A. FOUR SLOTS IN BASE FOR MOUNTING

1.38

(35)

19.65 (499)

20.05 (509)

19.20 (487)

N.A.

17.25 (438) (CENTERED)

CV-400-I

Now Available...12th Edition

VISA

Mas ter Car dMasterCard

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 Drawings

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.

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 dents have graduated. Tuition is low and the training is “hands on”

For details write: Lincoln Welding School

headquarters in Cleveland, Ohio. Over 100,000 stu-

22801 St. Clair Ave. Cleveland, Ohio 44117-1199.

Practical exercises and examples develop the reader’s 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 Durable, cloth-covered board binding.

$4.50 postage paid U.S.A.

There is a 10%

discount on all orders of $50.00 or more for shipment at one time to one location.

ability

11”

Mainland

and ask for bulletin ED-80 or call 216-383-2259 and ask

for the

Welding School Registrar.

Lincoln Welding School

BASIC COURSE $700.00

5 weeks of fundamentals

Orders 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. Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery. UPS Shipping for North America Only.

All prepaid orders that request UPS shipment please add: $5.00 For order value up to $49.99 $10.00 For order value between $50.00 & $99.99 $15.00 For order value between $100.00 & $149.00

For North America invoiced orders over $50.00 & 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. METHOD 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 Credit Card - Telephone: _______________________________________________

Account No.

USE THIS FORM TO ORDER:

BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.

|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Exp Date |_|_| |_|_|

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199

Name: _______________________________________________

Address: _______________________________________________

_______________________________________________

Signature as it appears on Charge Card:

Month Year

______________________

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80)

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

(ED-45)

Educational Video Information Incentive Management $5.00 IM

(ED-93)

James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC Foundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515)

New Lessons in Arc Welding $5.00 L

How to Read Shop Drawings $4.50 H

A New Approach to Industrial Economics $5.00 NA

Pipe Welding Charts $4.50 ED-89

SUB TOTAL

Additional Shipping Costs if any

TOTAL COST

WARNING

Spanish

AVISO DE

PRECAUCION

● 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 mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR 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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• 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

Lincoln Electric CV-400-I User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual