Lincoln Electric IM480 User Manual

For use with machines having Code Numbers: 10084 thru 10087, 11087, 11088, 11089

R

LISTED

170G

U

L

RETURN TO MAIN MENU

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.

CV-400

11354, 11355, 11835, 11836

IM480-C

August, 2011

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

i

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 fi elds m ay interf ere wi th some pacemak ers, a nd
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 e lectr ode 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.

ii

SAFETY

ii

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.

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.

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 ma y 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 within applicable OSHA PEL and
ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

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.d. 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.

vapors

to

5.e. 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.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING

SPARKS can

cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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

6.b. 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.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use on ly com pr essed 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. Re ad and foll ow the inst ru ctions o n c ompressed 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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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 nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

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

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

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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

-6-

TABLE OF CONTENTS

Page

Safety Precautions .............................................................................................................2-5

Introductory Information .......................................................................................................7

Meaning of Graphic Symbols ............................................................................................8-11

General Machine Description..............................................................................................12

Recommended Processes & Equipment ............................................................................12

Design Summary..............................................................................................................12-14

Operational Features & Controls ...............................................................................12-14

Technical Specifications .....................................................................................................15

Installation ........................................................................................................................16-18

Safety Precautions .......................................................................................................16

Location ........................................................................................................................16

Stacking........................................................................................................................16

Input Wiring ..................................................................................................................16

Output Connections......................................................................................................17

Installation of Field Installed Options .........................................................................17-18

Installation of Equipment Required for Recommended Processes ..............................18

Operating Instructions.........................................................................................................19

Safety Precautions .......................................................................................................19

Power Source Operation ..................................................................................................19-21

Duty Cycle ....................................................................................................................19

To Set Polarity ..............................................................................................................20

Control Descriptions...................................................................................................19-20

Maintenance .......................................................................................................................21

Routine Maintenance....................................................................................................21

Troubleshooting................................................................................................................21-24

Procedure for Replacing P.C. Boards.................................................................................25

Miscellaneous System Checks.........................................................................................25-27

Wiring Diagrams...............................................................................................................28-29

Warranty Information ...................................................................................................Back Cover

Parts Pages...............................................................................................................P-236,P-234-K

-7-

MEANINGS OF GRAPHIC SYMBOLS

The CV-400 nameplate has been designed to use international symbols in describing the function of the various
components. Below are the symbols used.

POWER ON-OFF SWITCH

Input (Power)

On

Off

OUTPUT CONTROL DIAL

V

OUTPUT CONTROL “LOCAL-REMOTE” SWITCH

Output Voltage (Control)

Increase/Decrease of Output (Voltage)

Remote Output Voltage Control

Local Output Voltage Control

– 8 –

CIRCUIT BREAKER

THERMAL PROTECTION LIGHT

Circuit Breaker

High Temperature

VOLTMETER SWITCH

Voltmeter

Positive Electrode

Negative Electrode

– 9 –

RATING PLATE

NEMA EW 1

Designates welder complies with National Electrical Manufacturers
Association requirements EW 1.

Three Phase Power

Transformer

Rectifier

Rectified DC Output

IP21

Constant Voltage Characteristic

Line Connection

Shielded Metal Arc Welding

Flux Cored Arc Welding

Degree of protection provided by the enclosure

– 10 –

WARNING IDENTIFICATION

EARTH GROUND CONNECTION

CHASSIS GROUND CONNECTION

Warning Identification

Signifying the Earth (Ground) Connection

Signifying the Chassis (Ground) Connection

– 11 –

GENERAL MACHINE DESCRIPTION

MACHINE OUTPUT CONTROL SWITCH “LOCAL”
OR “REMOTE”

The CV-400 is an SCR controlled three phase DC
power source. It is designed with a single range
potentiometer control.

RECOMMENDED PROCESSES
& EQUIPMENT

The CV-400 is supplied as a constant voltage power
source only. It is designed for all Innershield
Outershield®and all solid wire and gas procedures
within the capacity of the machine. The output char­acteristics have been optimized for these CV process­es without use of a variable arc control.

The CV-400 is designed to be used with the LN-7,
LN-7 GMA, LN-8, LN-9, LN-9 GMA, LN-22, LN-23P*,
LN-25, or LN-742 semiautomatic wire feeders, the NA-3,
NA-5 and NA-5R automatics within the capacity of the
machine. The CV-400 Diode option is required to uti­lize the cold start and cold electrode sensing features
of the NA-3, NA-5 and NA-5R.

* For “Cold” gun use K350 Adapter Kit.

®

,

The machine output voltage can be controlled by
either the “OUTPUT CONTROL” on the machine con­trol panel, the output control on the wire feed unit, or
an optional “remote control” that is available. This
switch selects the mode of control, either “LOCAL” or
“REMOTE”.

POLARITY SELECTION

Polarity selection is made by appropriately connecting
the electrode and work welding cables to either the

+” stud or to the “-” stud. Select “VOLTMETER”

“
switch for “+” or “-” electrode, for the remote (#21)

work sensing lead.

VOLTMETER SWITCH “+” ELECTRODE OR “-”
ELECTRODE

This switch selects electrode polarity for the remote
(#21) work sensing lead of automatic or semiautomat­ic equipment.

115 VOLT POWER SWITCH

DESIGN SUMMARY

Operational Features & Controls

ARC CHARACTERISTICS

Through the unique combination of the transformer,
three phase rectifier, capacitor bank, and output
choke design, in conjunction with the solid state con­trol system, an outstanding constant voltage welding
performance is achieved with a fixed pinch setting
optimized for the most popular arc characteristics.

OUTPUT VOLTAGE CONTROL

The OUTPUT voltage control, a small 2 watt poten­tiometer, is calibrated from 1 to 10.

The power input contactor operates from an auxiliary
115 volt transformer that is energized through the
POWER toggle switch on the machine control panel.
“ I ” is on and “0” is off.

PILOT LIGHT

A white light on the machine control panel indicates
when the power source input contactor is closed. This
means the main power transformer and all auxiliary
and control transformers are energized.

THERMAL PROTECTION LIGHT

An amber light on the machine control panel indicates
when either of the two protective thermostats have
opened. Output power will be removed but input
power will still be applied to the machine.

INPUT CONTACTOR

The power source is equipped with an input contactor.

– 12 –

AUXILIARY POWER CONNECTIONS

SOLID STATE CONTROL SYSTEM

The power source is equipped to furnish nominally
115 volt AC and 42 volt AC auxiliary power for operat­ing wire feeding equipment, etc. The auxiliary power
is available at the 14-pin MS-style connector recepta­cle on the control panel and/or at a terminal strip
behind the hinged control panel on the front of the
power source. 115V AC is available at receptacle
pins A and J, and terminals 31 and 32. 42V AC is
available only at receptacle pins I and K. The 115V
AC and the 42V AC are isolated circuits and each is
protected by a 10 amp circuit breaker.

REMOTE CONTROL CONNECTIONS

Remote control connections are available both at a
14-pin connector receptacle located on the control
panel, and on terminal strips with screw connections
located behind the hinged control panel on the front of
the power source.

OUTPUT CONNECTIONS

The output terminals are recessed on the case front
and labeled “

INPUT CONNECTIONS

The three input lines are brought in through the rear
panel of the power source and attached to the input
contactor. Removal of the removable access panel
makes the contactor accessible for the input cable
connections.

INPUT LINE VOLTAGE COMPENSATION

The power source is equipped with input line voltage
compensation as standard. For a line voltage fluctua­tion of ±10% the output will remain essentially con­stant. This is accomplished through the feedback net­work in the control circuit.

SOLID STATE OUTPUT CONTROL

+” and “-”.

The Control PC Board is located behind the control
panel which hinges down for easy access to the
board. The Snubber PC Board is mounted on the
back of the case front.

MACHINE COOLING

The fan pulls air in through the louvered front of the
machine over the internal parts and exhausts out the
louvered rear of the machine. The fan motor is fully
enclosed, has sealed ball bearings, requires no lubri­cation, and operates when the power switch is turned
on.

CASE FEATURES

The machine uses a 32” (813mm) long base. The low
profile case facilitates installation of the machine
under a workbench and stacking the machines three
high to conserve floor space.

The case front incorporates a recessed hinged control
panel where all the machine controls are mounted.
This recessed panel protects the controls and mini­mizes the possibilities of accidental contact. This con­trol panel can be easily opened to permit access to
the enclosed section which contains the terminal
strips, PC board, etc.The output lead terminals are
also recessed to avoid any object or person acciden­tally coming in contact with an output terminal.

The individual case sides are removable for easy
access for internal service or inspection. These are
removable even though the machines are stacked
three high.

The case rear, top section, is equipped with a remov­able access panel. This provides easy access to the
input contactor, easy connection and reconnection of
input leads, and easy access for service or inspection.

Although the machine is designed for use in rain-sheltered
environments, the transformer and choke assembly
are dipped in a special corrosion resistant epoxy
paint.

The output of the welder is electronically controlled by
SCRʼs instead of mechanical contactors, providing
extra long life for highly repetitive welding applica­tions.

A permanent lifting hook is located at the top of the
machine and is positioned so that it acts as nearly as
possible through the center of gravity. This lift hook is
so positioned that it fits without interference under the
base of the second machine when stacking.

– 13 –

PARALLELING

There are no provisions on the CV-400 to permit par­alleling.

DIODE OPTION (Factory installed only)

The CV-400 Diode option is required to utilize the cold
start and cold electrode sensing features of the NA-3,
NA-5 or NA-5R. When this option is not used with an
NA-3, NA-5 or NA-5R, see the CV-400 / NA-3,
CV-400 / NA-5 or CV-400 / NA-5R connection dia
for instructions on how to disable this circuit. If the cir­cuit is not disabled, the wire cannot be inched down.

METER OPTION

Factory installed Ammeter and Voltmeter

gram

Machine & Circuit Protection
(Thermal Protection Light)

The power source is thermostatically protected with
proximity thermostats against overload or insufficient
cooling. One thermostat is located on the nose of the
center bottom primary coil and a second thermostat is
attached to the lead connecting the secondaries.
Both thermostats are connected in a series with the 2­4 circuit. If the machine is overloaded, the primary
thermostat will open, the output will be zero, and the
thermal protection light will be on; the fan will continue
to run. The secondary thermostat will open either with
an excessive overload or insufficient cooling. The out­put will be zero and the protection light will be on; the
fan will continue to run. When the thermostats reset
the protection light will be off.

The power source is also protected against overloads
on the SCR bridge assembly through an electronic
protection circuit. This circuit senses an overload on
the power source and limits the output to 550 amps by
phasing back the SCRʼs.

Protection is provided to protect the circuitry from
accidental grounds. If the customer accidentally
“grounds” 75, 76, or 77 to the positive output lead, the
output will be reduced to a low value, thus preventing
any damage to the machine. If the ground occurs
between 75, 76, 77 and the negative output lead, one
of the PC board “self-restoring” fuses will blow, pre­venting any machine damage. After the ground is
cleared, the fuses automatically reset within a few
seconds.

– 14 –

TECHNICAL SPECIFICATIONS

Model
Type
Frequency

Output Rating

Amperes
Volts NEMA EW1

IEC 974-1

Duty Cycle

Output Range (Min.)

(Max.)

Max. O.C.V.

Input Ratings

Standard Voltages

Single Voltages (Available)
Rated Current
Input kVA
Power Factor
Efficiency
Idle Current
Idle Power

CV-400

K1346

60 Hz

DC

500 450 400

40 38 36

-- -- --

50% 60% 100%

60A 12V

500A 42V

46

230/460

230/460/575

Yes

77A @ 400A 34V (230V)

30.7 @ 400A 34V
.65 @ 400A 34V

71% @ 400A 34V

5.2A (230V)
.9 KW

Optional Features

Remote Control Adapter Cable
115V Starter Circuit
Suitable Undercarriages
Remote output Control

Other Features

Net Weight

Dimension Print

Wiring Diagram

Standards Compliance

Operating Temperature

Yes

Standard

Yes
Yes

Stackable Case

383 Lbs (174 kg)

M12244-7

L9269

L9270 (230/460/575 Only)

NEMA EW1

UL/CSA

IP21

-40°C to +40°C

– 15 –

INSTALLATION

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.

• Always wear dry insulating gloves.

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

FUMES AND GASES can be danger-

ous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

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

WELDING SPARKS can cause fire or

explosion.

• Keep flammable material away.

• Do not weld on closed containers.

APPLICATION LIMITATIONS

There are no provisions on the CV-400 for paralleling,
and outdoor operations without rain sheltering is not
recommended.

LIMIT ON STACKING

WARNING

FALLING EQUIPMENT can cause

injury.

• Do not lift this machine using lift bale if
it is equipped with a heavy accessory
such as trailer or gas cylinder.

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not stack more than three high.

• Do not stack the CV-400 on top of any other
machine.

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

The units may be stacked three high by observing the
following safety precautions.

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

ARC RAYS can burn eyes and skin.

• Wear eye, ear and body

protection.

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

See additional warning information at

front of this operatorʼs manual.

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

CORRECT OPERATIONAL USE

The machine should be located in a clean, dry place
where there is free circulation of clean air such that air
movement in through the front and out through the
back will not be restricted. Dirt and dust that can be
drawn into the machine should be kept to a minimum.
Failure to observe these precautions can result in
excessive operating temperatures and nuisance shut­down of the machine.

INSTALLATION DATA

Input Rating Recommended input wire and fuse sizes for maximum rated output.

In addition, follow latest National Electrical Code and Local Code.

Input Wire Size

Amperes**(Type 75°C Copper Wire Size

on Conductors in (Copper Conductors)

Voltage Hertz Nameplate Conduit)AWG AWG FUSE SIZE CATALOG

230 60 77 3 (27mm2) 8 (10mm2) 100 REN-100

460 39 8 (8.4mm2) 10 (5.3mm2) 50 RES-50

575 31 10 (5.3mm2) 10 (5.3mm2) 40 RES-40

1. Make sure the first or bottom unit is setting on a
level, well supported surface.

2. The units must be stacked with their fronts flush,
making sure the two holes in the base rails of the
unit being stacked on top are over the two holes
located on the top front corners of the unit it is
being stacked on. Fasten the units together with
5/16 bolts, nuts and lockwashers through these
holes.

3. Remove fastening bolts before lifting unit off stacks.

Input Power Connections

By removing the rear access panel the three phase
input power is connected to the three line terminals on
the input contactor, and the earth grounding lead to
the grounding terminal on the input box floor marked
with the symbol. Install the reconnect panel
links for the proper input voltage per the diagram
inside the access panel cover.

See Installation Data below:

*

Minimum Grounding

BUSSMANN SUPER-LAG

FUSE SIZE AND

CATALOG NUMBER***

NUMBER

jumper

pasted

*

Ambient temperature of 40°C (104°F).

**

At rated output of 400A, 100% duty cycle.

***

Use only Bussmann Super-Lag fuses specified. Other fuses may not protect the welder and may cause
overheating and possible fire damage.

– 16 –

CAUTION

REMOTE CONTROL ADAPTER CABLE (K864)

Failure to follow these instructions can cause immedi­ate failure of components within the machine.

When powering welder from a generator be sure
to turn off the welder first, before generator is
shut down
in order to prevent damage to welder.

Output Cable Connections

The output leads are connected to the output termi­nals marked “

+” and “-”.

They are located at the lower
right and lower left corners of the front panel. The
CV-400 provides 1/2” studs for weld cable connection.

Output Cables

CABLE SIZES FOR COMBINED LENGTH OF

ELECTRODE AND WORK CABLE

MACHINE LOAD

CABLE LENGTHS

UP TO 50 ft

(15m)

50 to 100 ft

(15-30 m)

400A

(100% DUTY

CYCLE)

3/0

85 mm

2

3/0

85 mm

2

500A

(50% DUTY

CYCLE)

2/0

67 mm

2

2/0

67 mm

2

STRAIGHT PLUG (14 PIN)
TO POWER SOURCE

CABLE RECEPTACLE (6 SOCKET)

TO: K857 REMOTE CONTROL

CABLE RECEPTACLE (14 SOCKET)
TO: LN-7 WIRE FEEDERS

A “V” cable 12” (.30m) long to connect a K857
Remote Control (6 pin connector) with a wire-feeder
(14-pin connector) and the machine (14-pin connec­tor). If a remote control or amptrol is used alone the
wire-feeder connection is then not used.

WARNING

ELECTRIC SHOCK can kill.

• 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.

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

CAPACITOR DISCHARGE CIRCUIT (K828-1)

100-150 ft

(30-46 m)

150-200 ft

(46-61 m)

200-250 ft

(67-76 m)

3/0

85 mm

3/0

85 mm

4/0

107 mm

3/0

2

85 mm

2

3/0

2

85 mm

2

4/0

2

107 mm

2

Installation of Field Installed Options

REMOTE OUTPUT CONTROL
(K857 WITH K864 ADAPTER OR K775 )

The K857 has a 6-pin MS-style connector. The K857
requires a K864 adapter cable which connects to the
14-pin connector on the machine.

The K775 consists of a control box with 28 ft (8.5m) of
four conductor cable. This connects to terminals 75, 76,
and 77 on the terminal strip and the case grounding
screw so marked with the symbol on the machine.
These terminals are located behind the control panel on
the front of the power source. This control will give the
same control as the output control on the

machine.

Circuit that mounts inside the CV-400.
Recommended when:

1) CV-400 is used in conjunction with any LN-23P or
older LN-8 or LN-9 semiautomatic wire-feeder.
Eliminates possible arc flash re-start of weld when
trigger interlock is used. Not required with current
LN-8 (above Code 8700), or LN-9ʼs with serial
numbers above 115187 (manufactured after
12/83), or any LN-9 having an L6043-1 Power PC
Board.

2) CV-400 is used with an LN-22 equipped with an
older K279 Contactor-Voltage Control Option.
Eliminates electrode overrun when gun trigger is
released. Not required when later K279 (above
Code 8800) is used.

3) CV-400 is used with any semiautomatic wire-feed­er and possible small spark, if electrode touches
work just after gun trigger is released, is objection­able.

Install per M17060 instructions included with the
Kit.

– 17 –

UNDERCARRIAGES (K817P, K841)

For easy moving of the machine, optional undercar­riages are available with polyolefin wheels (K817P) or
a platform undercarriage (K841) with mountings for
two gas cylinders at rear of welder.

Install per instructions provided with undercarriage.

Installation of Equipment Required for
Recommended Processes

WIRE FEEDER CONTROL CABLE CONNECTIONS

For control cable with 14-pin connector:

Connect control cable to 14-pin connector on the front
panel of the machine. See the appropriate connection
diagram for the exact instructions for the wire feeder
being used. Refer to “115VAC and 42VAC Auxiliary
Power and Control Connections” section for connector
pin functions.

A cover (Lincoln Electric Part Number S17062-3) is
available for the unused 14-pin connector to protect it
against dirt and moisture.

For control cable with terminal strip connectors:

The control cable from the wire feeding equipment is
connected to the terminal strips behind the control
panel. A strain relief box connector is provided for
access into the terminal strip section. A chassis
ground screw is also provided below the terminal strip
marked with the symbol for connecting the auto­matic equipment grounding wire. See the appropriate
connection diagram for the exact instructions for the
wire feeder being used. Refer to “115VAC and 42VAC
Auxiliary Power and Control Connections” section for
access to terminal strips.

CONNECTION OF CV-400 TO LN-22 OR LN-25

a) Turn off all power.

b) Connect a jumper from “2 to 4” on terminal strip

TS2 or jumper pins “C to D” in 14-pin connector
plug ( a K484 14-pin jumper plug is available).

c) Connect the electrode cable to the output terminal

of polarity required by electrode. Connect the work
lead to the other terminal.

d) Place the OUTPUT CONTROL Switch at “LOCAL”

position unless a Remote Control is connected to
the CV-400.

NOTE: The output terminals are energized at all

times.

– 18 –

OPERATING INSTRUCTIONS

Safety Precautions

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service
this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

• This next section applies to CV-400ʼs without
Capacitor Discharge Option:

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

When using a CV-400 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 can restart
if the electrode touches the work or ground during
these several seconds.

the

POWER SOURCE OPERATION

Duty Cycle and Time Period

The CV-400 is rated at the following duty cycles:

Duty Cycle* Amps Volts

100% 400 36

60% 450 38
50% 500 40

* Based upon a 10 minute time period. (i.e., for 60%

duty cycle, it is 6 minutes on and 4 minutes off).

Overloading the power source may result in opening
of an internal protective thermostat as indicated by the
amber thermal protection light turning on.

STARTING THE MACHINE

The POWER toggle switch at the extreme right side of
the control panel in the “ I “ position energizes and
closes the three phase input contactor from a 115 volt
auxiliary transformer. This in turn energizes the main
power transformer.

The machine is de-energized when the POWER
switch is in the “0” position.

The white light next to the POWER switch indicates
when the input contactor is energized.

OUTPUT VOLTAGE CONTROL DIAL

The Output control dial at the right of the control panel
is a continuous control of the machine output voltage.
The control may be rotated between minimum and
maximum to adjust the machine output, even while
welding.

The machine is equipped with line voltage compensa­tion as a standard feature. This will hold the output
constant except at maximum output of the machine,
through a fluctuation of ±10% input line voltage.

– 19 –

OUTPUT CONTROL “LOCAL-REMOTE” SWITCH

The Output Control toggle switch on the control panel
labeled “Local-Remote” gives the operator the option
of controlling the output at the machine control panel
or at a remote station. For remote control, the toggle
switch is set in the “Remote” position and controlled at
the wire feed unit control, or by connecting a K775
control to terminals 75, 76, and 77 on the terminal
strip at the front of the machine, or by connecting a
K857 control with a K864 adapter to the 14-pin con­nector on the front of the machine. For control at the
machine control panel (Output Voltage control dial),
the toggle switch is set in the “Local” position.

(Exception: When used with an LN-9, LN-9 GMA or
NA-5 wire feeder, the Output Control switch must be
in the “Remote” position or automatic shutdown of the
LN-9 or NA-5 may occur.)

POLARITY SELECTION

Polarity selection is made by appropriately connecting
the electrode and work welding cables to either the

+” stud or to the “-” stud. Select “Voltmeter” switch

“
for “+” or “-” electrode for the remote (#21) work sens-

ing lead.

VOLTMETER SWITCH

FRONT VIEW OF 14-PIN CONNECTOR
RECEPTACLE

K=42

A=32

B=GND

LN

C =2

D=4

E=77

J=31

I=41

H=21

G=75

F=76

M

PIN LEAD NO. FUNCTION

A 32 115 VAC
B GND Chassis Connection
C 2 Trigger Circuit
D 4 Trigger Circuit
E 77 Output Control
F 76 Output Control
G 75 Output Control
H 21 Work Connection
I 41 42 VAC
J 31 115 VAC
K 42 42 VAC
L --- --­M--- --­N--- ---

Select “+” for positive electrode or “-” for negative
electrode. This switch selects electrode polarity for the
remote (#21) work sensing lead of automatic or semi­automatic equipment.

THERMAL PROTECTION LIGHT

The amber thermal protection light will be lit if either of
the two protective thermostats have opened. The out­put power will be disabled but input power will still be
applied to the welder.

115 VAC and 42 VAC AUXILIARY POWER AND
CONTROL CONNECTIONS

14-Pin Connector

The 14-pin connector receptacle (type MS-3102A-2D­27SX) supplies auxiliary power.

42 VAC is available at receptacle pins I and K.
A 10 amp circuit breaker protects this circuit.

115 VAC is available at receptacle pins A and J. A 10
amp circuit breaker protects this circuit. Note that the
42 VAC and 115 VAC circuits are electrically isolated
from each other.

– 20 –

Terminal Strip Connections

MAINTENANCE

Terminal strip TS2 located behind the hinged control
panel on the front of the power source supplies 115
VAC. A 10 amp circuit breaker protects this circuit.
This 115 VAC is also available in the 14-pin connec­tor.

Terminal strip TS1 also located behind the hinged
control panel allows for connecting of a K775 remote
control to terminals 75, 76, and 77.

A chassis ground screw is provided below the terminal
strips marked with the symbol for connecting the
automatic equipment grounding wire or remote control
grounding wire.

To gain access to the terminal strips simply remove
the two #10 sheet metal screws from the top of the
welder nameplate. Tilt panel forward so it rests in a
horizontal position. See Table above for lead number
functions.

MACHINE AND CIRCUIT PROTECTION

The power source is thermostatically protected with
proximity thermostats against overload or insufficient
cooling. One thermostat is located on the nose of the
center bottom primary coil and a second thermostat is
attached to the lead connecting the secondaries. Both
thermostats are connected in series with 2-4 circuit. If
the machine is overloaded, the primary thermostat will
open, the output will be zero, the amber thermal pro­tection light will be on and the fan will continue to run.
The secondary thermostat will open either with an
excessive overload or insufficient cooling. The output
will be zero, the amber protection light will be on and
the fan will continue to run. When the thermostats
reset the protection light will be off.

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service
this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

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

Routine 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. Blow out
the machine at regular intervals.

3. In extremely dusty locations, dirt may accumulate
on the remote control terminal strip. Wipe or blow
this terminal strip off at regular intervals. This is
particularly important in damp locations.

TROUBLESHOOTING

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service
this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

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

The power source is also protected against overloads
on the SCR bridge assembly through the solid state
fault protection circuit. This circuit senses an overload
on the power source and limits the output to approxi­mately 550 amps by phasing back the SCRʼs.

Protection is provided to protect the circuitry from
accidental grounds. If leads 75, 76, or 77 are acciden­tally “grounded” to the positive output lead, the output
will be reduced to a low value, thus preventing any
damage to the machine. If the ground occurs between
75, 76, 77 and the negative output lead, one of the PC
board electronic “self-restoring” fuses will blow, pre­venting any machine damage. After the ground is
cleared, the fuses automatically reset within a few
seconds.

– 21 –

TROUBLESHOOTING GUIDE

Trouble Cause What To Do

Input contactor (CR1 chatters).

Machine input contactor does not
operate.

Machine input contactor operates,
but no output when trying to weld.

1. Faulty input contactor (CR1).

2. Low line voltage.

1. Supply line fuse blown.

2. Contactor power circuit dead.

3. Broken power lead.

4. Wrong input voltage.

5. Open input contactor coil.

6. POWER “I/O” switch (S1) not

closing.

1. Circuit between #2 (C ) and #4
(D) is not being closed.

2. Electrode or work lead loose or
broken.

3. Open main transformer (T1) pri­mary or secondary circuit.

4. Defective Control PC Board.

5. Primary or secondary ther­mostats open.

1. Repair or replace.

2. Check input power.

1. Replace if blown - look for reason
first.

2. Check control transformer T2
and associated leads.

3. Check input voltage at contactor.

4. Check voltage against instruc­tions.

5. Replace coil.

6. Replace switch.

1. Make sure trigger circuit is being
closed.

2. Repair connection.

3. Repair

4. Replace. See Procedure for
Replacing PC Boards.

5. Amber thermal protection light is
on: Check for overheating; make
sure fan is operating and there is
no obstruction to free air flow.

Machine has minimum output and
no control.

Machine has high output and no
control.

1. Terminals 75, 76, or 77 grounded
to positive

1. Terminals 75, 76, or 77 grounded
to negative

output.

output.

1. Check 75, 76, or 77 for ground to
positive output circuit. Nearly
zero ohms to ground indicates a
grounded circuit. A value greater
than a few thousand ohms is nor­mal. Self-restoring fuses on PC
Board automatically reset within
a few seconds after ground is
cleared.

1. Check 75, 76, or 77 for ground to
negative output circuit. Nearly
zero ohms to ground indicates a
grounded circuit. A value greater
than a few thousand ohms is nor­mal. Self-restoring fuses on PC
Board automatically reset within
a few seconds after ground is
cleared.

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 Field Service Facility for technical troubleshooting assistance before you proceed.

– 22 –

Trouble Cause What To Do

Machine has low output and no con­trol.

Machine does not have maximum
output.

1. Output Control “Local-Remote”
switch (S2) in wrong position.

2. Output Control switch faulty.

3. Open in feedback circuitry.

4. Faulty Control PC Board.

5. Output control potentiometer cir­cuit open (Lead 75).

1. One input fuse blown.

2. One phase of main transformer
open.

3. Faulty Control PC Board.

4. Output control potentiometer
defective.

5. Output control potentiometer
Leads 210, 211, or 75 open.

1. Check position of switch.

2. Check switch and replace if
faulty.

3. Check wiring and control PC
Board wiring harness plugs.

4. Replace. See Procedure for
Replacing PC Boards.

5. Check and replace potentiometer
if faulty. Check wiring of Lead
#75.

1. Check and replace if blown after
checking for reason for blown
fuse.

2. Check for open and repair.

3. Replace. See Procedure for
Replacing PC Boards.

4. Check and replace if faulty.

5. Check and repair broken leads.

Machine will not shut off.

Variable or sluggish welding arc.

Output control not functioning on the
machine.

1. Input contactor contacts frozen.

2. Defective Power “I/O”

switch, (S1).

1. Poor work or electrode connec­tion.

2. Welding leads too small.

3. Welding current or voltage too
low.

4. Defective main SCR bridge.

1. Output Control “Local-Remote”
switch (S2) in wrong position.

2. Faulty Output Control switch.

3. Faulty Output Control potentiometer.

4. Leads or connections open in
control circuit.

5. Faulty Control PC Board.

1. Check and replace if necessary.

2. Replace.

1. Check and clean all connections.

2. Check table in instruction manual.

3. Check procedures for recom­mended settings.

4. Check and replace if defective.

1. Place switch in “Local”.

2. Check and replace if found faulty.

3. Check and replace if found faulty.

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

5. Replace. See Procedure for
Replacing PC Boards.

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 Field Service Facility for technical troubleshooting assistance before you proceed.

– 23 –

Trouble Cause What To Do

Output control not functioning on
“Remote” control.

Poor arc striking with semiautomatic
or automatic wire feeders.

Poor arc characteristics.

1. Output Control switch in wrong
position.

2. Faulty Output Control switch.

3. Faulty remote control poten­tiometer.

4. Leads or connections open in
control circuit.

5. Faulty Control PC Board.

1. Poor work connection.

2. Improper procedures.

3. Defective Control PC Board.

1. Defective Control PC Board.

2. Capacitor(s) in output circuit
failed. A failure is indicated if the
small vent plug on top of a
capacitor is raised or blown out.

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. Replace. See Procedure for
Replacing PC Boards.

1. Work connection must be ade­quate for application.

2. Adjust procedures for improved
starting.

3. Replace. See Procedure for
Replacing PC Boards.

1. Replace. See Procedure for
Replacing PC Boards.

2. Replace entire bank of capaci­tors. Do not
capacitors.

WARNING: The liquid electrolyte
in these capacitors is toxic. Avoid
contact with any portion of your
body. Clean up vented electrolyte
using rubber gloves and a water
dampened cloth. Any electrolyte
which gets on skin, clean with
soap and water.

replace individual

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 Field Service Facility for technical troubleshooting assistance before you proceed.

– 24 –

Procedure for Replacing PC Boards

CHECKING SNUBBER PC BOARD

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service
this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

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

When a PC board is suspected to be defective, the
following procedure must be followed:

1. Visually inspect the PC board. If the board has
fuses, check to see if any are blown. Are any of
the components damaged? Is a conductor on the
back side of the board damaged? If electrical dam­age is visible on the PC board, inspect the
machine wiring for grounds or shorts to avoid
damaging a new PC board. Install a new PC board
only after a visual inspection of the PC board and
machine wiring is satisfactory.

2. If the problem is remedied by a new PC board,
install the old PC board and see if the problem still
exists. If the problem does not return with the old
board:

a. Check the PC board harness plug and PC

board plug for contamination, corrosion or
oversize.

b. Check leads in the harness for loose connec-

tions.

In case of an SCR malfunction or failure, the Snubber
PC Board should be checked. Turn the machine off
and remove the sides of the machine. Board is mount­ed on back of the case front.

1. Visually inspect the Board for overheated compo­nents or damaged components.

CHECKING OUTPUT CONTROL RHEOSTAT ON
MACHINE

Turn machine off (“0” position).

Remove the screws from the hinged control panel and
open the panel.

Turn the Output Control switch to “Remote”.

Disconnect the harness plug from the Control PC
Board.

With an ohmmeter on X1K, connect it to lead 210 and
75 on R4.

Exercise caution to avoid damaging rheostat tabs.

Rotate the Output control rheostat. The resistance
reading should be from around zero to 10K ohms.
Check the resistance reading between 77 and 75 on
the terminal strip. The reading must be 10K ohms. No
reading will indicate an open rheostat and a low read­ing will indicate a shorted or partially shorted rheostat;
in either case, replace.

CONNECTING THE REMOTE CONTROL TO THE

MACHINE

Extreme caution must be observed when installing or
extending the wiring of a remote control. Improper
connection of this unit can lead to loss of control
and/or poor welding. Only the green lead can and
should be grounded to the machine case. When
extending the standard remote control, make sure the
leads are the same and the splice is waterproof. Be
very careful not to ground the cable when in use and
donʼt let the lugs touch against the case.

OUTPUT VOLTAGE

The open circuit voltage of the machine should be
adjustable from 10 to 46 volts. If any other condition
exists, refer to the Troubleshooting Guide.

FAULT PROTECTION OPERATION

The overload protection circuit, in the Control Board,
will limit the welding current (heat) to approximately
550 amps if a short or overload is applied to the
machine.

POWER “ I/O “ SWITCH CHECK

1. Turn off the machine input power (“0” position). S1

has 115 volts across it when the input power is
connected.

2. Isolate the switch to be tested by removing all con­necting leads.

3. Check to make sure the switch is making open
and closed connections with a V.O.M. meter. Put
ohmmeter on X1 scale. The meter should read
zero resistance with switch “I” and infinite with
switch “0”.

4. Put the ohmmeter on X1K scale and measure the
resistance between the terminal and the case of
the machine (touch a self-tapping screw). Reading
should be infinite.

5. If either step (3) or step (4) fails, replace the
switch.

– 25 –

REMOTE CONTROL CHECK

Disconnect the remote output control and connect an
ohmmeter across 75 and 76 and rotate the rheostat in
the remote control. The resistance reading should go
from zero to 10K ohms. Repeat with ohmmeter across
77 and 76 with same results. Connect ohmmeter
across 75 and 77. 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
rheostat. Check cable for any physical damage.

resistance in both directions. An open diode will
have an infinite or high resistance in both direc­tions and a good diode will have a low resistance
in Step b. and a much higher resistance in Step c.

3. Power Silicon Controlled Rectifier Test

The SCR must be mounted in the heat sink when
making this test.

a. Connect the ohmmeter (set to the X10 scale) leads

to the anode and cathode.

POWER RECTIFIER BRIDGE ASSEMBLY
CHECKING PROCEDURE

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service
this equipment.

• Turn the input power off at the fuse
box before working on equipment.

• Do not touch electrically hot parts.

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

1. Bridge and Device Isolation

Disconnect the following, shown in Diagram 1:

a. Unplug P3 (G1, G2, G3, and 204) from the Control

PC Board.

b. Unplug P5 from the Snubber PC Board.

c. Secondary leads X1, X2, and X3 from the anodes

of the SCRʼs and cathodes of the diodes.

d. Disconnect positive bridge lead from shunt and

positive capacitor bank lead and from lug with dual
204 leads.

b. Reverse the leads of the ohmmeter from Step a.

c. A shorted SCR will indicate zero or an equally low

resistance in one or both directions.

d. Establish the polarity of the ohmmeter. Connect

the positive lead to the gate and the negative lead
to the cathode.

e. An open gate circuit will have an infinite or high

resistance. A good gate circuit will read a low
resistance, but not zero ohms. If gate circuit reads
zero ohms, check gate harness for shorts between
gate leads and 204 before replacing SCR.

e. Perform following steps 2 and 3. If diodes and

SCRʼs are not shorted, bridge test is completed. If
any device appears shorted, disconnect the cath­ode lead of each diode (4 total) and repeat steps 2
and 3.

2. Power Diode Test

a. Establish the polarity of the ohmmeter leads and

set to X10 scale.

b. Connect the ohmmeter positive lead to anode and

negative lead to the cathode.

c. Reverse the leads of the ohmmeter from Step b.

d. A shorted diode will indicate zero or an equally low

– 26 –

POWER RECTIFIER BRIDGE

DIAGRAM 1

PLUG TO SNUBBER BOARD

P5

220

223

221 222

D1 D2 D3

SCR1 SCR2 SCR3

X

1

X

2

ANODE

CATHODE

GATE

204

CATHODE

X

ANODE

220

_

3

To (+) side

of capacitor

bank

D4

SHUNT

+

Gate leads

plug to Control

P.C. board

P3

G1 G2 G3

204

204

204

To T1 main

transformer

+

_

To plug

P1

– 27 –

WIRING DIAGRAM FOR CODES 10084 thru 10084, 11354, 11835

Enhanced Diagram

– 28 –

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.

A

L9270

WIRING DIAGRAM FOR CODES 10087, 11087, 11088, 11089, 11055, 11836

CV-400 WIRING DIAGRAM

– 29 –

L9270

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.

NOTES

CV400

NOTES

CV400

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 electro-

dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Gardez à l’écart de tout matériel

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-

inflammable.

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

• N’opérez pas avec les panneaux

• Anlage nie ohne Schutzgehäuse

• Mantenha-se afastado das partes

• Não opere com os paineis abertos

guardas quitadas.

ouverts ou avec les dispositifs de
protection enlevés.

oder Innenschutzverkleidung in
Betrieb setzen!

moventes.

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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com