Lincoln Electric SVM136-A User Manual

IDEALARC

For Machines with Code Numbers 10084 thru 10087

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 CONT AINED THROUGHOUT .

And, most importantly, think

before you act and be careful.

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SVM136-A

November 1997

CV-400

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SERVICE MANUAL

World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.Tel.(216) 481-8100

i i

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 saf ety highlights.For additional saf ety inf ormation, 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

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

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.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.

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FOR ENGINE powered equipment.

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 weld-

ing 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 Vbelts, gears, fans and all other moving parts when starting, operating or repairing equipment.

IDEALARC CV-400

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.

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

ii ii

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” par ts 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 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.

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.

vapors

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5.e. Also see item 1.b.

IDEALARC CV-400

Mar ‘95

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” par ts 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.

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Mar ‘95

IDEALARC CV-400

iv iv

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.

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

7. Quand on ne soud 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.

e pas, poser la pince à une endroit isolé de

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.P orter 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.

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.

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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

IDEALARC CV-400

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

v v

IDEALARC CV-400

Page

Safety...............................................................................................................................................i-i-v

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

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Electrical Input Connections........................................................................................................A-3

Reconnect Procedure .................................................................................................................A-6

Output Connections ....................................................................................................................A-6

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

Safety Precautions......................................................................................................................B-2

General Description ....................................................................................................................B-3

Controls and Settings..................................................................................................................B-5

Welding Operation ......................................................................................................................B-6

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

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

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

Options/Accessories...................................................................................................................C-2

Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders...............................C-3

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

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance.............................................................................................D-2

Major Component Locations.......................................................................................................D-3

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair................................................................................................Section F

How to Use Troubleshooting Guide............................................................................................F-2

PC Board Troubleshooting Procedures......................................................................................F-3

Troubleshooting Guide ................................................................................................................F-4

Test Procedures........................................................................................................................F-10

Oscilloscope Waveforms...........................................................................................................F-28

Replacement Procedures..........................................................................................................F-32

Retest After Repair....................................................................................................................F-53

Parts Manual ...............................................................................................................................P-236

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DEC-97

Section A-1 Section A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

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

Technical Specifications ..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation ..............................................................................................................A-3

Lifting....................................................................................................................................A-3

Stacking................................................................................................................................A-3

Tilting....................................................................................................................................A-3

Electrical Input Connections .......................................................................................................A-3

Ground Connection...............................................................................................................A-4

Input Power Supply Connections..........................................................................................A-4

Input Wire and Fuse Size.....................................................................................................A-5

Reconnect Procedure .................................................................................................................A-6

Output Connections ....................................................................................................................A-6

Connect Electrode and Work Leads to Output Terminals ....................................................A-6

Connect Wire Feeders..........................................................................................................A-8

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IDEALARC CV-400

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - IDEALARC CV-400

INPUT - THREE PHASE ONLY

Standard Voltage Input Current at Rated Output

230/460 77A/39A @ 400A 36V

RATED OUTPUT

Duty Cycle Welding Output Volts at Rated Amps

100% 400 36*

60% 450 38 50% 500 40

OUTPUT

Current Voltage Maximum Open Auxiliary

Range Range Circuit Voltage Power

60 - 500 Amps 12 - 42 Volts 46 VDC 115 VAC, 10 Amps

42 VAC, 10 Amps

RECOMMENDED INPUT WIRE AND FUSE SIZES

Fuse Type 75° C Type 75° C

Input Voltage/ Input Amps (Super Lag) Copper Wire in Copper Ground

Frequency Rating on or Breaker Conduit AWG Wire in Conduit

Volts/Hz Nameplate Size (IEC) Sizes AWG (IEC) Sizes

230 77 125 3 (27 mm2) 6 (13 mm2) 460 39 60 8 (8.4 mm2) 10 (5.3 mm2)

PHYSICAL DIMENSIONS

Height

27.5 in. (699 mm) 22.2 in. (565 mm) 32.0 in. (813 mm) 357 lbs. (162 kg)

* No added capacity over NEMA rated 36V at 400 amps.

Width Depth Weight

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IDEALARC CV-400

A-3 A-3

INSTALLATION

Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Turn power switch off before connecting or disconnecting cables or connections.

• Always connect grounding terminal to a proper electrical earth ground.

Only qualified personnel should install, use, or service this equipment.

The IDEALARC CV-400 weighs 357 pounds (162 kilograms). A permanent lift hook is located at the top of the machine, positioned at the center of gravity for stable lifting.

STACKING

IDEALARC CV-400s may be stacked three high. The bottom machine must be on a stable, hard, level surface capable of supporting the weight of up to three machines (1071 pounds/486 kilograms). Be sure that the two holes in the top front corners of the bottom machine line up with the holes in the base rails of the machine above. Fasten the machines together with 5/16" bolts, lockwashers, and n uts through these holes. The lift hook is positioned so that it fits without interference under the base of the second machine.

TILTING

Place the machine on a secure, level surface. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound.

LOCATION AND VENTILATION

Place the IDEALARC CV-400 where clean, cooling air can flow freely in through the front louvers and out through the rear louvers. Keep dust, dirt, and other foreign materials that can be drawn into the machine to a minimum. Failure to observe these precautions can lead to excessive operating temper atures and nuisance shut-downs.

THE CV-400 carries an IP-21 environmental rating. Locate indoors or shelter from falling water such as rain.

LIFTING

WARNING

FALLING EQUIPMENT can cause injury.

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

• Lift only with equipment of adequate lifting capacity.

ELECTRICAL INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the input power is as specified on the rating plate, located on the case front control panel. See

Input supply line entry is through a hole in the case rear top panel. A removable door covers the input connection box, which contains the input contactor (CR1) and reconnect panel assembly for multiple voltage connection. Input power is connected to the three line terminals on the input contactor. See

Figure A.1

Figure A.2

• Be sure the machine is stable when lifting.

• Do not stack more than three high.

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

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IDEALARC CV-400

A-4 A-4

INSTALLATION

FIGURE A.1

RATING PLATE LOCATION

1. RATING PLATE

GROUND CONNECTION

The frame of the welder must be grounded. An ear th grounding lead must be connected to the grounding terminal, marked on the input box floor with the symbol

(See

cations

Figure A.2

page for proper ground wire size.

). Refer to

Technical Specifi-

INPUT SUPPLY CONNECTIONS

Be sure the voltage, phase, and frequency of the input power is the same as specified on the rating plate.

WARNING

ELECTRIC SHOCK can kill.

• Have a qualified electrician install and service this equipment.

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

• Do not touch electrically hot parts.

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IDEALARC CV-400

A-5 A-5

INSTALLATION

FIGURE A.2

REAR PANEL

1. INPUT SUPPLY LINE ENTRY HOLE

2. INPUT CONTACTOR CR1

3. RECONNECT PANEL/JUMPER LINKS

4. GROUND TERMINAL

INPUT WIRE AND FUSE SIZE

Fuse the input circuit with the super lag fuse recommended in the ning of this section or use delay type1circuit breakers. Choose an input and grounding wire size according to local or national codes; also see the

Specifications

than recommended may result in "nuisance" shut-offs from welder inrush currents, even if you are not welding at high output currents.

Also called "inverse time" or "thermal/magnetic" circuit breakers. These circuit breakers trip faster as the magnetude of the fault current increases.

INPUT POWER SUPPLY CONNECTIONS

Technical Specifications

at the begin-

Technical

. Using fuses or circuit breakers smaller

FIGURE A.3

Have a qualified electrician connect the input power leads to the L1, L2, and L3 terminals of the input contactor. Follow all national and local electrical codes. Use a three-phase line. Install the reconnect panel jumper links (see Figure A.3) for the proper input voltage. See the connection diagram located on the inside cover of the access panel cover. Also refer to

Reconnect Procedure

later in this section.

1. INPUT SUPPLY LINE

2. INPUT CONTACTOR

3. RECONNECT PANEL/JUMPER LINKS

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IDEALARC CV-400

A-6 A-6

INSTALLATION

RECONNECT PROCEDURE

Multiple input voltage welders are shipped from the factory connected for the highest voltage listed on the machine's rating plate. Before installing the welder, be sure the reconnect panel is connected for the proper voltage.

Failure to follow these instructions can cause immediate failure of components in the welder.

To reconnect a multiple voltage machine to a different voltage, remov e input pow er and change the position of the jumper links on the reconnect panel. Follow the input connection diagram, located on the inside access panel cover, appropriate for your machine's input voltage.This same connection diagram is shown in Figure A.4 below.

FIGURE A.4

INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZ

OUTPUT CONNECTIONS

CONNECT ELECTRODE AND WORK LEADS TO OUTPUT TERMINALS

The output (welding) cables are connected to the output terminals marked "+" and "-" .These 1/2" terminals are located at the lower right and lower left corners of the front panel. See

See

Table A.1

bined lengths of electrode and work cables.

Figure A.5

for recommended cable sizes for com-

Do not operate with covers removed

Disconnect input power before servicing

Do not touch electrically live parts

Only qualified persons should install, use or service this equipment

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK

LINES

INPUT

{

GND

L3 L2 L1

CR1

CONTACTOR

PILOT TRANSF.

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK

LINES

INPUT

{

GND

THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.

CR1

CONTACTOR

PILOT TRANSF.

DUAL VOLTAGE MACHINE

IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.

NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.

2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS. DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE. SECURE THE REMAINING HEX NUTS IN PLACE.

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.

2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION.

3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES.

5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.

INPUT SUPPLY CONNECTION DIAGRAM

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IDEALARC CV-400

A-7 A-7

INSTALLATION

FIGURE A.5

OUTPUT TERMINAL CONNECTIONS

1. NEGATIVE (-) WELDING CABLE CONNECTION

2. POSITIVE (+) WELDING CABLE CONNECTION

TABLE A.1 - CABLE SIZES FOR COMBINED LENGTH

OF ELECTRODE AND WORK CABLE

MACHINE LOAD

400A 500A

(100% DUTY (50% DUTY

CABLE LENGTHS CYCLE) CYCLE)

UP TO 50 ft 3/0 2/0

(15 m) 85 mm

67 mm

50 to 100 ft 3/0 2/0

(15 to 30 m) 85 mm

67 mm

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100 to 150 ft 3/0 3/0 (30 to 46 m) 85 mm

85 mm

150 to 200 ft 3/0 3/0 (46 to 61 m) 85 mm

85 mm

200 to 250 ft 4/0 4/0 (67 to 76 m) 107 mm

107 mm

IDEALARC CV-400

A-8 A-8

INSTALLATION

CONNECT WIRE FEEDERS

The wire feeder control cable can connect to the CV400 at the 14-pin amphenol on the front of the machine (with the appropriate adapter cable) or the terminal strips behind the hinged control panel cover. A strain relief box connector is provided for cable access to the terminal strips. The wire feeder grounding wire connects to a chassis ground screw provided near the terminal strips and marked with the ground symbol . See the ic instructions for connecting the following automatic and semiautomatic wire feeders to the CV-400:

Automatic Wire Feeders: NA-3, NA-5, NA-5R. Semiautomatic Wire Feeders: LN-7, LN-7 GMA, LN-8,

LN-9, LN-9 GMA, LN-22, LN-23P, LN-25, LN-742.

Accessories

section of this manual for specif-

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IDEALARC CV-400

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

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

Safety Precautions......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes....................................................................................................B-3

Operational Features and Controls ......................................................................................B-3

Design Features ..................................................................................................................B-3

Welding Capability................................................................................................................B-4

Limitations.............................................................................................................................B-4

Controls and Settings..................................................................................................................B-5

Welding Operation.......................................................................................................................B-6

Local Control.........................................................................................................................B-6

Remote Control.....................................................................................................................B-6

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

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

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IDEALARC CV-400

B-2 B-2

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section of operating instructions before operating the machine.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

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

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Observe additional Safety Guidelines detailed in the beginning of this manual.

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IDEALARC CV-400

B-3 B-3

OPERATION

GENERAL DESCRIPTION

The IDEALARC CV-400 is an SCR controlled threephase input, DC output power source for welding.It uses a single range potentiometer control.The welder's unique combination of transformer, three phase hybrid rectifier, capacitor bank, output choke, and solid state control system deliver outstanding performance.

RECOMMENDED PROCESSES

The IDEALARC CV-400 is a constant voltage power source only. It is recommended for all open arc processes including Innershield and all solid wire and gas procedures within its capacity of 60 to 500 amps.

The CV-400 can be connected to wire feeding equipment, including:

• Automatic wire feeders NA-3, NA-5, and NA-5R. (Requires the CV -400 Diode Kit option to use the cold start and cold electrode sensing features of these feeders.)

• Semiautomatic wire feeders LN-7, LN-7 GMA, LN8, LN-9, LN-9 GMA, LN-22, LN23P, LN-25, and LN-742.

OPERATIONAL FEATURES AND CONTROLS

The following operational controls are standard on the IDEALARC CV-400:

• Power Source Pilot Light

• ON/OFF Power Toggle Switch

• Output Control Potentiometer

• Output Control Switch (with Local or Remote positions)

• Auxiliary Power Connections for Wire Feeder and Other Equipment (115V and 42V)

• Thermal Protection Indicator Light

• Voltmeter "+" Electrode or "-" Electrode Switch

DESIGN FEATURES

• Input line voltage compensation keeps output constant for fluctuations of ±10%.

• SCR control.

• Hinged front control panel provides easy access to printed circuit boards and other control circuitry.

• Fully enclosed fan motor with permanently lubricated, sealed ball bearings needs no maintenance.

• Fully recessed control panel protects controls and minimizes accidental contact.

• Recessed output terminals reduce chance of accidental contact.

• Low profile case permits installation under a workbench.

• Removable rear access panel provides easy access to input contactor and input lead connections.

• Removable case sides provide easy access for service or inspection, even when machines are stacked.

• Double-dipped transformer, SCR bridge, and choke resist corrosion.

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IDEALARC CV-400

B-4 B-4

OPERATION

WELDING CAPABILITY

The CV-400 has the following duty cycle ratings. If the duty cycle is exceeded, a thermal protector will shut off the machine output until it cools to normal operating temperature. The amber thermal protection indicator light will turn on until the machine cools.

Duty Cycle* Amps Volts

100% 400 36

60% 450 38 50% 500 40

*Based on a 10 minute time period. For example, a 60% duty cycle means 6 minutes on and 4 minutes off.

LIMITATIONS

The IDEALARC CV-400 has no provisions for paralleling. It should not be used outdoors without rain sheltering.

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IDEALARC CV-400

B-5 B-5

OPERATION

CONTROLS AND SETTINGS

All operator controls and settings are located on the case front assembly. See Figure B.1 for their locations.

FIGURE B.1 – CASE FRONT CONTROLS

1. POWER SOURCE PILOT LIGHT

2. ON/OFF POWER TOGGLE SWITCH

3. OUTPUT CONTROL POTENTIOMETER

4. OUTPUT CONTROL SWITCH (WITH LOCAL OR REMOTE POSITIONS)

5. DC VOLTMETER

1. POWER SOURCE PILOT LIGHT: This light indi- cates that the power source input contactor is energized (closed).This also means that the main power transformer and all auxiliary control transformers are energized.

2. ON/OFF POWER TOGGLE SWITCH: Energizes or deengergizes the input contactor. The switch turns the machine ON or OFF. Position "I" is ON; position "0" is OFF.

3. OUTPUT CONTROL POTENTIOMETER: Controls output voltage.

4. OUTPUT CONTROL SWITCH (WITH LOCAL OR REMOTE POSITIONS): Selects the mode of control. In the "Local" position, control is by the machine control panel. In the "Remote" position, control is by either a wire feeder unit or through an optional remote control device.

5. DC VOL TMETER (OPTIONAL): Displays actual output voltage.

6. DC AMMETER (OPTIONAL): Displays actual output current.

6. DC AMMETER

7. AUXILIARY POWER CONNECTIONS FOR WIRE FEEDER AND OTHER EQUIPMENT (115V AND 42V)

8. VOLTMETER "+" ELECTRODE OR "-" ELECTRODE SWITCH

9. THERMAL PROTECTION INDICATOR LIGHT

34567

7. AUXILIARY POWER AND REMOTE CONTROL

CONNECTIONS FOR WIRE FEEDER AND OTHER EQUIPMENT (115V AND 42V): The 14-pin amphe-

nol receptacle provides either 115 or 42 VAC as well as remote control connections. Terminal str ips with screw connections are located behind the hinged control panel for hard wired control. A strain relief connector is provided for cable entry. The 42 VAC auxiliary is not available at the terminal strip.

8. VOLTMETER "+" ELECTRODE OR "-" ELEC- TRODE SWITCH: Selects the electrode polarity for the remote work sensing lead (#21) when using automatic or semiautomatic wire feeders. It must agree with the actual electrode polarity chosen and with the wire feeder polarity switch on the feeder.

9. THERMAL PROTECTON INDICATOR LIGHT: This light indicates that either of the two protective thermostats has opened. Welding output is disabled but input power is still applied.

10. 42 VAC AUXILIARY CIRCUIT BREAKER: This 10

amp breaker protects the 42 VAC auxiliar y circuit.

11. 115 VAC AUXILIAR Y CIRCUIT BREAKER:T

his 10

amp breaker protects the 115 VAC auxiliar y circuit.

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IDEALARC CV-400

B-6 B-6

OPERATION

WELDING OPERATION

LOCAL CONTROL

The following procedures are for using the CV-400 in the local control mode of operation. For remote control of the machine, see the Remote Control section.

Before operating the machine, make sure you have all materials needed to complete the job. Be sure you are familiar with and have taken all possible safety precautions before starting work. It is important that you follow these operating steps each time you use the machine.

1.Turn on the main AC input power to the machine.

2. Set the VOLTMETER "+" or "-" switch to the appropriate position.

- Set toggle to " Electrode Negative" position if the

electrode is connected to the negative (-) output terminal.

- Set toggle to "Electrode Positive" position if the elec-

trode is connected to the positive (+) output terminal.

3. Set the OUTPUT CONTROL switch to "Local." (Exception: when using an LN-9, LN-9 GMA, or NA5 wire feeder , set the s witch to "Remote." Otherwise, the wire feeder may automatically shut down.)

4. Set the ON/OFF switch to the ON position (I). The power source pilot light glows and the fan star ts.

5. Set the OUTPUT CONTROL Potentiometer to the desired voltage.

6. Make the weld.

REMOTE CONTROL

The toggle switch on the control panel labeled "Output Control Remote" gives you the option of controlling the machine output from a remote location. In the "Remote" position a wire feeder with remote control capabilities or a remote control device such as a K775 must be connected to the CV-400. See the

Accessories

mation.

section for wire feeder installation infor-

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IDEALARC CV-400

B-7 B-7

OPERATION

OVERLOAD PROTECTION

The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling. One thermostat is located on the nose of the center bottom primary coil and a second thermostat is attached to the lead connecting the secondaries. Both thermostats are connected in series with 2-4 circuit. If the machine is overloaded, the primary thermostat will open, the 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.

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 SCR’s.

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.

AUXILIARY POWER

On machines above code 9400, the IDEALARC CV400 can provide nominally 115 volts AC and 42 volts AC auxiliary power for operating wire feeding equipment and other accessories.This power is available at the 14-pin amphenol on the control panel and/or at the terminal strip behind the hinged control panel on the case front. On the amphenol, 115 volts AC is available at pins A and J (Domestic and Export models only); 42 volts AC is available at pins I and K. On the terminal strip, 115 volts AC is available at terminals 31 and 32; 42 volts AC is not available at the terminal strip. The two circuits, 115 volts A C and 42 v olts AC, are isolated; and each is protected by a 10 amp circuit breaker.

FRONT VIEW OF 14-PIN CONNECTOR RECEPTACLE

K=42

A=32

B=GND

D=4

E=77

J=31

I=41

H=21C=2

G=75

F=76

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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 V A C

J 31 115 V A C K 42 42 VAC L --- ---

M --- --N --- ---

IDEALARC CV-400

B-8 B-8

NOTES

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IDEALARC CV-400

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES -

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

Options/Accessories ...................................................................................................................C-2

Options/Accessories .............................................................................................................C-2

Factory Installed Options......................................................................................................C-2

Field Installed Options ..........................................................................................................C-2

Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders................................C-3

Automatic Wire Feeders NA-3, NA-5....................................................................................C-3

Semiautomatic Wire Feeders LN-7, LN-8, LN-9 ...................................................................C-6

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IDEALARC CV-400

C-2 C-2

ACCESSORIES

OPTIONS/ACCESSORIES

The following options/accessories are av ailable f or your CV-400 from your local Lincoln Electric Distributor.

FACTORY INSTALLED OPTIONS

Diode Option - This internally installed option allows use of the cold start and cold electrode sensing features of the NA-3, NA-5, or NA-5R automatic wire feeders. See the topic

CV -400

Ammeter and Voltmeter - Display output current and

voltage when welding.

FIELD INSTALLED OPTIONS

The following options/accessories are available from your local Lincoln Distributor.

Undercarriage (K817P) - Includes a platform and polyolefin wheels for easily moving the welder.

Undercarriage (K841) - Includes a platform, wheels, and brackets for supporting the welder and two gas cylinders.

Remote Output Control (K775 or K857 with K864 Adapter Plug) - The K857 has a 6-pin MS-style con-

nector.The K857 requires a K864 adapter cable which connects to the 14-pin connector on the CV-400.

Connecting the NA-3 [NA-5] to the

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 marked with the symbol on the machine. These terminals are located behind the control panel on the front. These devices will give the same control as the output control on the machine.

Remote Control Adapter Cable (K864) - A "V" cable 12 inches (.30 m) long to connect a K857 Remote Control with a wire-feeder control cable (14-pin connector) and the machine (14-pin connector).If a remote control is used alone, the wire-feeder connection is not used. See Figure C.1.

Capacitor Discharge Circuit (K828-1) - Mounts inside the CV-400. Recommended when:

• CV-400 is used in conjunction with any LN-23P or older LN-8 or LN-9 semiautomatic wire-feeder. Eliminates possible arc flash re-start of weld when trigger interlock is used. Not required with current LN8 (above Code 8700), or LN-9s with serial numbers above 115187 (manufactured after 12/83), or any LN9 having an L6043-1 Power PC Board.

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

• A small spark is objectionable if electrode touches work just after the trigger is released.

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FIGURE C.1

REMOTE CONTROL ADAPTER CABLE (K864)

STRAIGHT PLUG (14 PIN) TO POWER SOURCE

IDEALARC CV-400

CABLE RECEPTACLE (6 SOCKET) TO K857 REMOTE CONTROL

CABLE RECEPTACLE (14 SOCKET) TO: L-7 WIRE FEEDER

C-3 C-3

ACCESSORIES

CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS

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.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

Auxiliary power for wire feeder operation is available at both a 14-pin amphenol and at terminal strips with screw-type connections located behind the hinged control panel on the front of the machine. The 14-pin amphenol can provide both 115 VAC (pins A and J) and 42 VAC (pins I and K). The ter minal strip provides only 115 VAC (terminals 31 and 32). The two circuits are isolated, and each is protected by a 10A circuit breaker.

NOTE: When using a CV-400 with wire feeders, there may be a small spark if the electrode contacts the work or ground within a few seconds after releasing the trigger. With some wire feeders, when the electrical interlock is in the ON position the arc can restart if the electrode touches the work or ground during these few seconds. Refer to K828-1 capacitor discharge circuit earlier in this section.

The following descriptions show how to connect the wire feeders using the terminal strip.

A UTOMATIC WIRE FEEDERS

CONNECTING THE NA-3 TO THE IDEALARC CV-400

1. Set the CV-400 PO WER toggle switch to the OFF (0) position.

2. Disconnect main AC input power to the CV-400.

3. Connect the wire feeder control cable leads to the CV-400 terminal str ip as shown in Figure C.2.

4. Connect the wire feeder control cable ground lead to the frame terminal marked .

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AUTOMATIC

CONTROL

BOX

NOTE: The CV-400 must be properly grounded.

FIGURE C.2

NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400

NA-3 WIRE FEEDER CONTROL CABLE

GND

2 31 32

75 76 77

TERMINAL

STRIPS

4 2

BLANK

31 32

75 76 77

NEGATIVE POSITIVE

TO WORK

IDEALARC CV-400

ELECTRODE CABLE TO AUTOMATIC EQUIPMENT

C-4 C-4

ACCESSORIES

5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or larg-

er insulated wire.Tape the bolted connection with insulating tape.

b.An S-16586- X remote voltage sensing work lead

is available for this purpose.

c. Keep the #21 lead electrically separate from the

work cable circuit and connection.

d. Tape the #21 lead to the work cable for ease of

use.

NOTE: The connection diagram shown in

Figure C.2

shows the electrode connected for positive polarity.To change polarity:

a. Set the CV-400 POWER toggle switch to the OFF

(0) position.

b.Move the electrode cable to the negative (-) output

terminal.

c. Move the work cable to the positive (+) output ter-

minal.

CONNECTING THE NA-5 TO THE IDEALARC CV-400

1. Set the CV-400 PO WER toggle switch to the OFF (0) position.

2. Disconnect main AC input power to the CV-400.

3. Connect the wire feeder control cable leads to the CV-400 terminal str ip as shown in Figure C.3.

4. Connect the wire feeder control cable ground lead to the frame terminal marked .

NOTE: The CV-400 must be properly grounded.

d. Set the VOLTMETER toggle switch to negative.

FIGURE C.3

NA-5 WIRE FEEDER CONNECTION TO THE CV-400

NA-5 WIRE FEEDER CONTROL CABLE

AUTOMATIC

CONTROL

BOX

GND

TERMINAL

STRIPS

4 2

BLANK

31 32

75 76 77

76 77

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IDEALARC CV-400

NEGATIVE POSITIVE

TO WORK

ELECTRODE CABLE TO AUTOMATIC EQUIPMENT

C-5 C-5

ACCESSORIES

5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or larg-

er insulated wire.Tape the bolted connection with insulating tape.

b.An S-16586- X remote voltage sensing work lead

is available for this purpose.

c. Keep the #21 lead electrically separate from the

work cable circuit and connection.

d. Tape the #21 lead to the work cable for ease of

use.

6.Connect NA-5 wire feeder control jumpers on Voltage Control Board. See the NA-5 operator's manual.

NOTE: For proper NA-5 operation, the electrode cables must be secured under the clamp bar on the left side of the NA-5 Control Box.

NOTE: The connection diagram shown in shows the electrode connected for positive polarity. To change polarity:

a. Set the CV-400 PO WER toggle s witch to the OFF (0)

position.

b.Move the electrode cable to the negative (-) output

terminal.

c. Move the work cable to the positive (+) output termi-

nal. d. Set the VOLTMETER toggle switch to negative (-). e. See

NA-5

manual for changing welding polarity.

Figure C.3

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IDEALARC CV-400

C-6 C-6

ACCESSORIES

SEMIA UTOMATIC WIRE FEEDERS

CONNECTING THE LN-7 TO THE IDEALARC CV-400 (TERMINAL STRIP)

1. Set the CV-400 PO WER toggle s witch to the OFF (0) position.

2. Disconnect main AC input power to the CV-400.

3. Connect the wire feeder control cable leads to the CV-400 terminal str ip as shown in Figure C.4.

4. Connect the wire feeder control cable ground lead to the frame terminal marked .

NOTE: The CV-400 must be properly grounded.

5. PERFORM THIS STEP ONLY IF THE LN-7 IS EQUIPPED WITH A METER KIT.

NOTE: If the work cable length is less than 25 feet and the connections to the work piece are secure, then wire feeder control cable lead #21 can be connected directly to the CV-400 terminal str ip.

Extend wire feeder control cable lead #21 so it can be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or larg-

er insulated wire.Tape the bolted connection with insulating tape.

b.An S-16586- X remote voltage sensing work lead

is available for this purpose.

c. Keep the #21 lead electrically separate from the

work cable circuit and connection.

d. Tape the #21 lead to the work cable for ease of

use.

6. Set voltmeter toggle switch to match electrode polarity.

NOTE: The connection diagram shown in Figure C4 shows the electrode connected for positive polarity.To change polarity:

a. Set the CV-400 POWER toggle switch to the OFF

(0) position

b.Move the electrode cable to the negative (-) output

terminal.

c. Move the work cable to the positive (+) output ter-

minal.

d. Set the VOLTMETER toggle switch to negative (-).

TO LINE-7 INPUT

CABLE

PLUG

FIGURE C.4

LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400

NA-7 WIRE FEEDER CONTROL CABLE

GND

4 2

TERMINAL

STRIPS

4 2

BLANK

31 32

75 76 77

76 77

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IDEALARC CV-400

NEGATIVE POSITIVE

TO WORK

ELECTRODE CABLE TO AUTOMATIC EQUIPMENT

C-7 C-7

ACCESSORIES

CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC CV-400

1. Set the CV-400 POWER toggle switch to the OFF (0) position.

2. Disconnect main AC input power to the CV-400.

3. Connect the wire feeder control cable leads to the CV-400 terminal strip as shown in Figure C.5.

4. Connect the wire feeder control cable ground lead to the frame terminal marked .

5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece.

a. Make a bolted connection using AWG #14 or

larger insulated wire. Tape the bolted connection with insulating tape.

b. An S-16586- X remote voltage sensing work lead

is available for this purpose.

c. Keep the #21 lead electrically separate from the

work cable circuit and connection.

d. Tape the #21 lead to the work cable for ease of

use.

NOTE: Using the extended #21 lead eliminates the need to use the LN-9's remote work lead accessory, which has a direct work lead jack.

6. Connect the LN-9 wire feeder control jumpers on the Voltage Control board. See LN-9 operator's manual.

NOTE: The connection diagram shown in Figure C.5 shows the electrode connected for positive polarity. To change polarity:

a. Set the CV-400 POWER toggle switch to the OFF

(0) position.

b. Move the electrode cable to the negative (-) out-

put terminal.

c. Move the work cable to the positive (+) output

terminal.

d. Set the VOLTMETER toggle switch on power

source to negative (-).

e. Set the voltmeter toggle switch on feeder (if

equipped) to match electrode polarity.

INPUT

CABLE

FIGURE C.5

LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400

LN-8 ORLN-9 WIRE FEEDER CONTROL CABLE

GND

4 2

TERMINAL

STRIPS

4 2

BLANK

31 32

75 76 77

76 77

NEGATIVE POSITIVE

TO WORK

ELECTRODE CABLE TO AUTOMATIC EQUIPMENT

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IDEALARC CV-400

C-8 C-8

NOTES

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IDEALARC CV-400

Section D-1 Section D-1

TABLE OF CONTENTS

-MAINTENANCE-

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

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance.............................................................................................D-2

Major Component Locations.......................................................................................................D-3

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IDEALARC CV-400

D-2 D-2

MAINTENANCE

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.

ROUTINE AND PERIODIC MAINTENANCE

WARNING

To avoid receiving an electric shock, keep electrode holders and cable insulation in good condition.

1. Disconnect power supply lines to the machine before performing periodic maintenance.

2. In extremely dusty locations, dirt may clog the air channels, causing the welder to run hot. Periodically blow out dust and dirt from the inside of the machine with a low pressure air system. Be sure to clean the following components thoroughly. See for their location.

• Main transformer

• Output studs

• Polarity switch

• Rectifier assembly

• Control box assembly

3. Dirt and dust may also accumulate on the remote control terminal strips. Wipe or blow off the terminal strips regularly, especially in damp locations.

Figure D.1

4. Inspect the welder output terminals and control cables for fraying, cuts, and bare spots.

5.The fan motor has sealed ball bearings and requires no maintenance.

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IDEALARC CV-400

D-3 D-3

MAINTENANCE

FIGURE D.1

Major Component Locations

1. BASE

2. CASE FRONT

3. OUTPUT TERMINALS

4. CONTROL PANEL

5. MAIN TRANSFORMER

6. CHOKE

7. SCR/DIODE BRIDGE

8. LEFT CASE SIDE

9. CASE TOP

10. RIGHT CASE SIDE

11. CASE BACK WITH FAN MOTOR ASSEMBLY

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IDEALARC CV-400

D-4 D-4

NOTES

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IDEALARC CV-400

Section E-1 Section E-1

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-

Theory of Operation .............................................................................................................Section E

General Description...............................................................................................................E-1

Input Line Voltage, Contactor and Main Transformer ............................................................E-2

Output Control, Rectification and Feedback..........................................................................E-3

Protective Devices and Circuits .............................................................................................E-4

SCR Operation ......................................................................................................................E-5

FIGURE E.1 – BLOCK LOGIC DIAGRAM

OUTPUT

CONTROL

TRANSFORMER

CONTROL

POWER

SWITCH

INPUT

CONTACTOR

CONTROL

BOARD

14 PIN AMPHENOL

REMOTE

CONTROL

MAIN

TRANSFORMER

R E C O N N E C T

115VAC

T E

42VAC

FAN

CONTROL BOARD

A L

SCR DIODE

HYBRID BRIDGE

F E E D B A C K

OUTPUT

CAPACITORS

SHUNT

NEGATIVE

OUTPUT

TERMINAL

F E E D B A C K

POSITIVE

OUTPUT

TERMINAL

GENERAL DESCRIPTION

The CV-400 is an SCR controlled three-phase DC power source. It is designed for all open arc constant voltage (CV) processes within the capacity of the machine. The output characteristics have been optimized for CV processes without the use of a variable arc control. Minimum to maximum output is obtained with a single potentiometer control.

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IDEALARC CV-400

E-2 E-2

THEORY OF OPERATION

FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER

OUTPUT

CONTROL

TRANSFORMER

CONTROL

POWER

SWITCH

INPUT

CONTACTOR

CONTROL

BOARD

14 PIN AMPHENOL

REMOTE

CONTROL

MAIN

TRANSFORMER

R E C O N N E C T

115VAC

42VAC

FAN

CONTROL BOARD

A L S

SCR DIODE

HYBRID BRIDGE

F E E D B A C K

OUTPUT

CAPACITORS

SHUNT

NEGATIVE

OUTPUT

TERMINAL

F E E D B A C K

POSITIVE

OUTPUT

TERMINAL

INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER

The desired three-phase input power is connected to the CV-400 through an input contactor, located in the input box at the rear of the machine. Two phases of the input line are also connected to the control transformer, which, through the power switch, supplies power to activate the input contactor.

A reconnect panel allows the user to configure the machine for the desired input voltage. This AC voltage is applied to the primary of the main transformer.

The transformer changes the high voltage, low current input power to a lower voltage, higher current output.

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The finishes or "neutrals" of the main secondary coils are connected together, and the three starts of the secondary windings are connected to the rectifier bridge assembly. In addition, the main transformer has separate and isolated 115VAC and 42VAC auxiliary windings. The 115VAC is available at the terminal strip and the 14 pin amphenol and is protected by a 10 amp circuit breaker. The 42VAC is available at the 14 pin amphenol only and is also protected by a 10 amp circuit breaker. The three 21VAC phase angle windings are also housed in the main transformer assembly. These windings provide power and "timing" for the control board.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

IDEALARC CV-400

E-3 E-3

THEORY OF OPERATION

FIGURE E.3 – OUTPUT CONTROL, RECTIFICATION AND FEEDBACK

OUTPUT

CONTROL

TRANSFORMER

CONTROL

POWER SWITCH

INPUT

CONTACTOR

CONTROL

BOARD

14 PIN AMPHENOL

REMOTE

CONTROL

MAIN

TRANSFORMER

R E C O N N E C T

115VAC

42VAC

FAN

CONTROL BOARD

A L S

SCR DIODE

HYBRID BRIDGE

F E E D B A C K

OUTPUT

CAPACITORS

SHUNT

NEGATIVE

OUTPUT

TERMINAL

F E E D B A C K

POSITIVE

OUTPUT

TERMINAL

OUTPUT CONTROL, RECTIFICATION AND FEEDBACK

The three-phase AC output from the main transformer secondary is rectified and controlled through the SCR/diode bridge. Output current and voltage is sensed at the shunt and output capacitors, respectively. This feedback information is processed in the control board. The control board compares the commands of the output control (or remote control) with the feedback information and sends the appropriate gate firing signals to the SCR/diode bridge. in this section.

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A "dry closure" of leads #2 and #4, either at the terminal strip or the 14 pin amphenol, signals the control board to apply gate firing signals to the SCR/diode bridge, which creates a DC voltage at the output of the bridge assembly. This output is filtered by the capacitors to reduce the ripple content of the waveform. Thus, a smoother DC output is created. The choke, which is in series with the negative output ter-

See SCR Operation

minal, stores energy and provides current filtering.

NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.

IDEALARC CV-400

E-4 E-4

THEORY OF OPERATION

FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT

THERMAL

LIGHT

#42 #240

TERMINAL

STRIP

CIRCUIT BREAKER

#41

PROTECTIVE DEVICES AND CIRCUITS

SECONDARY THERMOSTAT

#24142A#

PRIMARY

THERMOSTAT

#41

#240

CONTROL BOARD

Two thermostats protect the CV-400 from excessive operating temperatures and overload conditions. Excess operating temperatures may be caused by insufficient cooling air or by operating the machine beyond the duty cycle and output rating. The primar y thermostat is located on the nose of the center bottom primary coil. The secondary thermostat is attached to the lead connecting the secondaries. Both thermostats are connected in series with the trigger circuits. If the machine is over-heated, the thermostats will open and output will be zero. The thermal protection light will glow and the fan will continue to run. See Figure E.4, CV-400 Trigger And Thermal Light Circuit. Under normal conditions the Thermal Light is "shorted out" by the circuit breaker and thermostat circuit. If the thermostats or the circuit breaker opens, more current will flow through the Thermal Light circuit, and the light will glow.

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Protection is also provided to protect the circuitry from accidental grounds. If the customer accidentally "grounds" 75, 76, or 77 to the positive output lead, the CV-400 output will be reduced to a very low value, thus preventing any damage to the machine. If the ground occurs between 75, 76, and 77 and the negative output lead, one of the PC board electronic "self-restoring" fuses will blow, preventing any machine damage. After the ground is cleared, the fuses automatically reset within a few seconds.

IDEALARC CV-400

E-5 E-5

THEORY OF OPERATION

FIGURE E.5 – SCR OPERATION

INPUT

CATHODE

OUTPUT

ANODE

GATE

NOTE: AS TH E GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED.

SCR OPERATION

A silicon controlled rectifier (SCR) is a three-terminal device used to control rather large currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON, and there is current flow from anode to cathode. In the ON state the SCR acts like a closed switch. When the SCR is turned OFF, there is no current flow from anode to cathode; thus the device acts like an open switch. As the name suggests, the SCR is a rectifier, so it passes current only during positive half cycles of the AC supply. The positive half cycle is the portion of the sine wave in which the anode of the SCR is more positive than the cathode.

When an AC supply voltage is applied to the SCR, the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state. The amount of time spent in the ON state is controlled by the gate.

An SCR is fired by a short burst current into the gate. This gate pulse must be more positive than the cathode voltage. Since there is a standard PN junction between gate and cathode, the voltage between these terminals must be slightly greater than 0.6V. Once the SCR has fired, it is not necessary to continue the flow of gate current. As long as current continues to flow from anode to cathode the SCR will remain on. When the anode to cathode current drops below a minimum value called holding current, the SCR will shut off. This normally occurs as the AC supply voltage passes through zero into the negative portion of the sine wave . If the SCR is turned on early in the positive half cycle, the conduction time is longer, resulting in greater SCR output. If the gate firing occurs later in the cycle, the conduction time is less, resulting in lower SCR output.

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IDEALARC CV-400

E-6 E-6

NOTES

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IDEALARC CV-400

Section F-1 Section F-1

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section.................................................................................Section F

How to Use Troubleshooting Guide .......................................................................................F-2

PC Board Troubleshooting Procedures..................................................................................F-3

Troubleshooting Guide ..................................................................................................F-4 - F-9

Test Procedures ...................................................................................................................F-10

Control Transformer (T2) Voltage Test...........................................................................F-10

Input Contactor Test ......................................................................................................F-13

Main Transformer (T1) Voltage Test...............................................................................F-16

Static SCR/Diode Rectifier Bridge Test .........................................................................F-21

Active SCR Test .............................................................................................................F-24

Oscilloscope Waveforms......................................................................................................F-28

Normal Open Circuit Voltage Waveform ........................................................................F-28

Typical Output Voltage Waveform - Machine Loaded....................................................F-29

Typical SCR Gate Voltage Waveform ............................................................................F-30

Abnormal Output Voltage Waveform - Machine Loaded...............................................F-31

Replacement Procedures ....................................................................................................F-32

Input Contactor (CR1) Cleaning/Replacement..............................................................F-32

Fan Motor and Blade Removal and Replacement ........................................................F-34

SCR/Diode Rectifier Assembly Removal and Replacement.........................................F-36

Mounting of Stud Type Diodes to Aluminum Heat Sinks...............................................F-44

Main Transformer Removal and Replacement..............................................................F-46

Retest After Repair ..............................................................................................................F-53

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IDEALARC CV-400

F-2 F-2

TROUBLESHOOTING & REPAIR

HO W TO USE TROUBLESHOOTING GUIDE

WARNING

Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. 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 two main categories: Output Problems and Welding Problems.

Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perf orm these tests/checks in the order listed. In general, these tests can be conducted without removing the case cover.

Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action” lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this section. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points, components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electr ic Service Depar tment for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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CAUTION

IDEALARC CV-400

F-3 F-3

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING

• Remove the PC Board from the static-shielding bag

ELECTRIC SHOCK can kill.

Have an electrician install and service this equipment. Turn the machine OFF before working on equipment. Do not touch electrically hot parts.

Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

PC Board can be damaged by static electricity.

• Remove your body’s static charge before opening the static-shielding bag. Wear an anti-static wrist

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

Reusable Container Do Not Destroy

strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

• If you don’t have a wrist strap, touch an unpainted, grounded, part of the equipment frame. Keep touching the frame to prevent static build-up . Be sure not to touch any electrically live parts at the same time.

and place it directly into the equipment. Don’t set the PC Board on or near paper, plastic or cloth which could have a static charge. If the PC Board can’t be installed immediately, put it back in the static-shielding bag.

• If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete.

• If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure symp-

tom has been corrected by the replacement PC board.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and substitute

it with the original PC board to recreate the original problem.

a. If the original problem does not reappear

by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by the

substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed

when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

• Tools which come in contact with the PC Board must be either conductive, anti-static or static-dissipative.

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IDEALARC CV-400

F-4 F-4

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

Machine is dead - no output - no fan - no pilot light.

The machine is dead - no output no fan - the pilot light is on.

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Contact your local authorized Lincoln Electric Field Service Facility for technical assistance.

1. Make sure the input power switch is ON.

2. Check the three-phase input voltage at the machine. Input voltage must match the rating plate and the reconnect panel.

3. Check for blown or missing fuses in the input lines.

1. Check the three-phase input voltage at the machine. Input voltage must match the rating plate and the reconnect panel.

2. Check for blown or missing fuses in the input lines.

RECOMMENDED COURSE OF ACTION

Contact the Lincoln Electric Service Department, (216) 3832531 or 1-800-833-9353 (WELD).

1. Check the input power switch (S1) for proper operation. See the Wiring Diagram.

2. Check the leads associated with the power switch (S1) and the control transformer (T2) for loose or faulty connections. See the Wiring Diagram.

3. Perform the

T ransformer T est.

1. Perform the

Test.

2. Check the associated leads for loose or faulty connections between the input contactor (CR1), the reconnect panel and the main transformer. See the Wiring Diagram.

Control

Input Contactor

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Depar tment for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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CAUTION

IDEALARC CV-400

3. Perform the

Test.

Main T ransformer

F-5 F-5

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The input contactor operates - the fan runs - the pilot light is on - but the machine has no welding output.

The input contactor (CR1) chatters.

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. If the amber thermal protection light is on, the primary or secondary thermostat is open. Allow machine to cool.

2. Make certain the output trigger circuit (#2 and #4) is being activated by a “closure.”

3. Check the 10 amp circuit breaker in the 42VAC circuit. Reset if necessary.

4. If remote control is not being used, make certain the Output Control switch (S2) is in the “Machine or Local” position.

5. Check for loose or faulty w elding cable connections.

1. Make certain the three-phase input voltage matches the machine rating plate and the reconnect panel.

RECOMMENDED COURSE OF ACTION

1. Perform the

Test.

2. Perform the

fier Bridge Test.

3. The control board may be faulty. Replace.

1. Perform the

Test.

Main T ransformer

SCR/Diode Recti-

Input Contactor

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before y ou proceed. Call 216383-2531 or 1-800-833-9353.

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CAUTION

IDEALARC CV-400

F-6 F-6

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The machine has high welding output and no control.

The machine has minimum (or very low) welding output and no control.

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. If remote control is being used, set the Output Control Switch (S2) to the “Machine or Local” position and control the weld output with the machine Output Control (R4). If the problem is solved, check the remote control unit or wire feeder and associated control cable.

2. Check the remote control leads for “grounds” to the negative welding output. If leads #75, #76 or #77 are “grounded”to the negative welding output, the machine output may go very high without control.

RECOMMENDED COURSE OF ACTION

Check the Output Control switch (S2) and associated wiring. See the Wiring Diagram.

2. Check feedback leads #220, #204, #205 and #206 for loose or faulty connections.

3. Perform the

Rectifier Bridge Test.

4. The control board may be faulty. Replace.

1. Check the Output Control (R4) and associated wiring. See the Wiring Diagram.

2. Check the Output Control switch (S2) and associated wiring. See the Wiring Diagram.

3. Perform the

Test.

Main Transformer

SCR/Diode

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Depar tment for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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2. Make certain the remote control leads (#75, #76, #77) are not grounded to the positive welding output.

3. Make certain the three-phase input voltage is correct and matches the machine rating and the reconnect panel.

CAUTION

IDEALARC CV-400

4. Perform the

ier Bridge Test.

5. The control board may be faulty.

SCR/Diode Rectif-

F-7 F-7

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The machine does not have maximum output.

The machine will not shut off when the power switch is put in the OFF position.

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Make sure the correct threephase input voltage is being applied to the machine.

2. If remote control is being used, set the Output Control switch (S2) to the “Machine or Local” position and control the weld output with the machine Output Control (R4). If the problem is solved, check the remote control unit or wire feeder and associated control cable.

1. Make sure the three-phase input

lines are connected correctly to the CV-400.

RECOMMENDED COURSE OF ACTION

1. Check the Output Control (R4). Normal resistance is 10,000 ohms. Also check associated wiring for loose or faulty connections. See the Wiring Diagram.

2. Check the Output Control switch (S2) and associated wiring. See the Wiring Diagram.

3. Perform the

Test.

4. Perform the

Rectifier Test.

5. The control board may be faulty. Replace.

1. Check the input power switch

(S1) and associated leads. See the Wiring Diagram.

Main Transformer

SCR/Diode Bridge

CAUTION

2. Perform the

Test.

Input Contactor

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before y ou proceed. Call 216383-2531 or 1-800-833-9353.

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IDEALARC CV-400

F-8 F-8

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

The output terminals are always electrically “hot.”

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

1. Remove any external leads that may be connected to the 14 pin amphenol or the terminal strip. If the problem disappears, the fault is in the control cable or wire feeder.

RECOMMENDED COURSE OF ACTION

1. Check for an internal short between leads #2 and #4. See the Wiring Diagram.

2. Remove plug J3 (SCR gate leads) from the control board. If the problem disappears, the control board may be faulty. Replace. If the output ter minals are still electrically “hot,” perform the

Bridge Test.

3. The snubber board may be faulty. Check or replace.

SCR/Diode Rectifier

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Depar tment for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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CAUTION

IDEALARC CV-400

F-9 F-9

TROUBLESHOOTING & REPAIR

TROUBLESHOOTING GUIDE Observe Safety Guidelines

detailed in the beginning of this manual.

PROBLEMS (SYMPTOMS)

POSSIBLE AREAS OF MISADJUSTMENT(S)

WELDING PROBLEMS

Poor arc characteristics. 1. Make sure the correct weld pro-

cedures are being used. (Electrode, Gas, etc.)

2. Check the welding cables for loose or faulty connections.

Poor arc striking with semiautomatic or automatic wire feeders.

1. Make sure the correct weld procedures are being used. (Electrode, Gas, etc.)

RECOMMENDED COURSE OF ACTION

1. Check the output capacitors and connections. A capacitor failure is indicated if the small vent plug on top of a capacitor is raised or blown out.

WARNING: The liquid 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.

2. The control board may be faulty.

1. The control board may be faulty.

2. Check the welding cables for loose or faulty connections.

The welding arc is variable and sluggish.

1. Check the input voltage at the CV -400, making sure the correct voltage and all three phases are being applied to the machine.

2. Make sure the welding process is correct for the machine settings.

3. Check the welding cables for loose or faulty connections. Also make sure cables are sized correctly for the welding current.

1. Perform the

fier Bridge Test.

2. Perform the

Test.

3. The control board may be faulty. Replace.

SCR/Diode Recti-

Main Transformer

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Depar tment for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

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IDEALARC CV-400

F-10 F-10

TROUBLESHOOTING & REPAIR

CONTROL TRANSFORMER (T2) V OL T A GE TEST

W ARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For y our safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

This procedure will determine if the correct voltage is being applied to the primary of the control transformer and induced on the secondary winding of the control transformer.

MATERIALS NEEDED

Volt/ohmmeter (Multimeter) 5/16” Nut driver IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this manual.)

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IDEALARC CV-400

F-11 F-11

TROUBLESHOOTING & REPAIR

CONTROL TRANSFORMER (T2) V OL T A GE TEST (continued)

FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS

TEST PROCEDURE

1. Disconnect the main input supply power to the machine.

2. With the 5/16” nut driver, remove the top, case sides, and rear input panel.

3. Locate the control transformer (T2) on the left side of the input box (facing the back of the machine). See Figure F.1.

4. Locate the control transformer primary leads (H1, H2, H3, etc.). See the Wiring Diagram.

NOTE: Unused leads should be taped. a. Inspect for broken or incorrect connec-

tions.

5. Locate control transformer leads X1 (top) and X2.

a. Lead X1 is connected to the input con-

tactor (CR1) coil located on the input side of the contactor. See Figure F.1.

b. Lead X2 is spliced into lead #231. See

the Wiring Diagram. Lead #231 is connected to the power switch (S1). See

Figure F.2.

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IDEALARC CV-400

F-12 F-12

TROUBLESHOOTING & REPAIR

CONTROL TRANSFORMER (T2) V OL T A GE TEST (continued)

FIGURE F.2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS

MACHINE FRONT

BACK OF CONTROL PANEL

LEAD #231 CONNECTION

METER PROBE

RIGHT SIDE VIEW

6. Test for 115VAC between leads X1 and #231.

NOTE: If the main AC input supply voltage varies, the control transformer voltage will vary by the same percentage.

a. Connect one end of an insulated alligator

clip to the X1 connection at the input contactor (CR1) coil. See Figure F.2.

b. Connect the other end of the alligator clip

to one of the meter probes. Be sure that neither the alligator clip nor the meter probe touches any metal surfaces.

c. Connect the other meter probe to the

#231 connection (top lead) at the power switch. See Figure F.2.

d. Apply input power to the CV-400.

7. Read the meter for 115VAC. a. If 115VAC is present, the control trans-

former is functioning properly.

b. If 115VAC is NOT present, go to Step 8.

8. If 115VAC is not present between leads X1

and #231, check the spliced connection between #231 and X2. Test for correct main input supply power to the control transformer primary windings (H1, H2, H3, etc.). Check the main input supply power hookup to the machine. See the Wiring Diagram.

a. If the correct main input supply power to

the control transformer primary windings is present AND the secondary voltage is not correct, the control transformer may be faulty. Replace.

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IDEALARC CV-400

F-13 F-13

TROUBLESHOOTING & REPAIR

INPUT CONTACTOR TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

DESCRIPTION

This test will determine if the input contactor is receiving the correct coil voltage and if the contacts are functioning correctly.

MATERIALS NEEDED

Volt/ohmmeter (Multimeter) 5/16” Nut driver IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this manual.) External 120VAC supply

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IDEALARC CV-400

F-14 F-14

TROUBLESHOOTING & REPAIR

INPUT CONTACTOR TEST (continued)

FIGURE F.3 – INPUT CONTACTOR CONNECTIONS

X1, #232

#233

TEST PROCEDURE

1. Disconnect the main input supply power to the machine.

2. With the 5/16” nut driver, remove the case top and the reconnect panel cover.

3. Locate the two leads connected to the input contactor coil, #233 and X1 #232 (top). See Figure F.3 for location.

4. Connect an AC voltmeter to the leads.

WARNING

Electric Shock can kill.

• With the input power on, there are high voltages inside the machine. Do not reach into the machine or touch any internal part of the machine while the power is on.

5. Apply the correct voltage to the machine and turn the power switch (S1) ON.

6. Check for 120VAC at the contactor coil leads. If the 120VAC is NOT present, with the power

switch (S1) on, check the power switch (S1) and associated circuitry. See the Wiring Diagram. Also perform the Control

Transformer (T2) Voltage Test.

If the 120VAC is present and the contactor does NOT activate, then the input contactor is faulty. Replace the input contactor.

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IDEALARC CV-400

F-15 F-15

TROUBLESHOOTING & REPAIR

INPUT CONTACTOR TEST (continued)

FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS

APPLY EXTERNAL

X1, #232

120 V AC HERE (X1, #232 AND #233 LEAD TERMINALS)

LR49598 0597

U V W

(L1) (L2) (L3)

AH# ACC730 - 8025B

(3186-30J755 18H)

LINCOLN ELECTRIC CO.

CRI SA M - 12161 - 61

#233

TEST FOR CONTACT CONTINUITY

1. Disconnect the main input supply power to the machine.

2. Remove the two leads connected to the input contactor coil, #233 and X1/#232. See Figure F.4 for location.

3. Using the external 120VAC supply , apply 120VAC to the terminals of the input contactor coil. If the contactor does NOT activate, the input contactor is faulty. Replace the input contactor.

LR49598 0597

U V W

(L1) (L2) (L3)

AH# ACC730 - 8025B

(3186-30J755 18H)

LINCOLN ELECTRIC CO.

CRI SA M - 12161 - 61

4. With the contactor activated, check the continuity across the contacts. (Zero ohms or very low resistance is normal.) See Figure F.4. If the resistance is high, the input contactor is faulty. Replace the input contactor.

5. When the contactor is NOT activ ated, the resistance should be infinite or very high across the contacts. If the resistance is low, the input contactor is faulty. Replace the input contactor.

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IDEALARC CV-400

F-16 F-16

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER (T1) VOLT A GE TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

This test will determine if the correct voltages are being applied to the primary windings of the Main Transformer (T1) and induced on the secondary winding, auxiliary windings, and phase angle windings.

MATERIALS NEEDED

Volt/ohmmeter (Multimeter) 5/16” Nut driver IDEALARC CV-400 wiring diagram (See the Electrical Diagrams section of manual.)

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IDEALARC CV-400

F-17 F-17

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)

FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS

TO MAIN TRANSFORMER LOCATIONS

TEST PROCEDURE

1. Set the ON/OFF power switch to OFF.

2. Disconnect main input supply power from the machine.

3. With the 5/16” nut driver, remove the case top and sides and the reconnect panel cover.

4. Inspect the input contactor, reconnect panel, and primary leads to the main transformer for loose or faulty connections. See Figure F.5.

a. Confirm that the reconnect panel is

connected properly for the three-phase main input power supplied to the machine. See the reconnect panel connection diagram located on the inside of the input box assembly access door.

5. Connect main input supply power to the machine.

6. Set the ON/OFF power switch to ON. a. Make sure the input contactor (CR1)

energizes and the fan runs.

7. Test with an AC voltmeter for proper main input supply voltage to the line side of the input contactor (CR1). See the Wiring Diagram.

a. L1 to L2. b. L2 to L3. c. L1 to L3.

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IDEALARC CV-400

F-18 F-18

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)

FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS

8. Read the meter. a. If proper voltage is present for all three

phases, proper main input supply voltage is being supplied.

b. If proper voltage is not present in any

or all of the three phases, check input fuses and leads.

9. Test with an AC voltmeter for proper main input supply voltage from the output side of the input contactor (CR1). See the Wiring Diagram and Figure F.5.

a. T1 to T2. b. T2 to T3. c. T1 to T3.

10. Read the meter. a. If proper voltage is present for all three

phases, the input contactor is working properly.

b. If the proper voltage is not present for

any or all of the three phases, the input contactor may be faulty. Replace the input contactor.

11. Test with an AC voltmeter for approximately 42VAC across each of the three main secondary start leads located at the SCR/Diode Rectifier Bridge. Remove the red insulating paint to achieve good contact if necessary. See Figure F.6. See the Wiring Diagram.

a. If one or more of the above voltage

tests are incorrect, check for loose or faulty connections.

b. If the connections are good, then the

main transformer may be faulty. Replace the main transformer.

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IDEALARC CV-400

F-19 F-19

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)

FIGURE F.7 – PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION

4 2

BLANK

31 32

14-PIN AMPHENOL

K=42

A=32

J=31

75 76 77

12. Test for 115VAC between leads #31 and #32 on the terminal strip. Also test for 42VAC between pin K (lead #42) and pin I (lead 41) in the 14-pin amphenol. See Figure F.7.

a. Remove the sheet metal screws from

the control box cover with the 5/16” nut driver and flip the cover down. It does not have to be completely removed to perform the tests.

b. If the above voltage checks are incor-

rect, check for loose or faulty wiring. Check continuity.

c. If the wiring is good, then the main

transformer may be faulty. Replace the main transformer.

B=GND

D=4

E=77

I=41

H=21C=2

G=75

F=76

13. Test with an AC voltmeter for 21VAC for each phase angle winding at plug P1 on the control board as shown in Figure F.8 and the accompanying table.

NOTE: If the main input supply voltage varies, the main transformer voltages will vary proportionately.

a. If the voltage is low, remove plug P1

and recheck the voltage for 21VAC. If the reading is normal, the control board may be faulty. Replace the control board.

b. If one or more of the voltage tests are

incorrect, check for loose or faulty wiring.

c. If the wiring is good, then the main

transformer may be faulty. Replace the main transformer.

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IDEALARC CV-400

F-20 F-20

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)

FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION

G2629-[ ] CV-400/CV-500-I CONTROL

#203

Plug P3

#204

#202

Plug P1 PHASE ANGLE WINDING VOLTAGES

From Lead # To Lead # Expected VAC

201 204 21 VAC

202 204 21 VAC

203 204 21 VAC

#201

Plug P1

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IDEALARC CV-400

F-21 F-21

TROUBLESHOOTING & REPAIR

STATIC SCR/DIODE RECTIFIER BRIDGE TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

This test will help determine if an SCR or diode is shorted or “leaky.” See the Machine Waveform Section in this manual for normal and abnormal output waveforms.

MATERIALS NEEDED

Analog Volt/ohmmeter (Multimeter) 5/16” Nut driver 9/16” Wrench IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this manual.)

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IDEALARC CV-400

F-22 F-22

TROUBLESHOOTING & REPAIR

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS

G2629-[ ] CV-400/CV-500-I CONTROL

Plug P3

#203

#204

#202

#201

Plug P1

TEST PROCEDURE

1. Disconnect the main input supply power to the machine.

2. With the 5/16” nut driver, remove the case top and sides.

3. Disconnect the welding cables from the welding output terminals.

4. Locate and remove molex plug P3 from the control board. See Figure F.9.

Plug P5

M15370-[ ] SNUBBER

5. Locate and remove molex plug P5 from the snubber board. See Figure F.9.

6. Locate and remove lead #204 from resistor R2 (7.5 ohms, 100 watts). See Figure F.14.

7. Using the 9/16” wrench, remove the positive capacitor strap lead and small lead terminal from the rectifier plate and output shunt junction. See Figure F.10.

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FIGURE F.10 – CAPACITOR STRAP LEAD CONNECTIONS

POSITIVE CAPACITOR STRAP LEAD

SMALL LEAD TERMINAL

IDEALARC CV-400

F-23 F-23

TROUBLESHOOTING & REPAIR

STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.11 – HEAT SINK AND SCR TEST POINTS

SCR ANODE

REMOVE ANY INSULA TING P AINT

8. Remove any red insulating paint from the heat sink test points. See Figure F.11.

NOTE: Do not disassemble the heat sink.

9. Measure the resistance from the anode to the cathode of SCR 1 using an analog volt/ohmmeter (multimeter) set at R x 1000 scale. See Figure F.11.

a. Reverse the meter leads and measure

the resistance from the cathode to the anode of SCR 1. See Figure F.11.

b. If a low resistance is measured in

either meter polarity, SCR 1 is faulty. Replace SCR 1.

10. Test the resistance of SCR 2 and SCR 3 using the same procedure described in Step 9.

11. Measure the resistance of diode D1 from anode (+probe) to cathode (-probe) using an analog ohmmeter set at R x 1000 scale. The resistance should be low. See Figure F.11.

CATHODE (SCR)

a. Reverse the meter leads and measure

the resistance from cathode (+probe) to anode (-probe) of diode D1. The resistance should be high. See Figure F.11.

b. If a low resistance is measured in both

meter polarities, diode D1 is shorted. Replace diode D1.

c. If a high resistance is measured in both

meter polarities, diode D1 is open. Replace diode D1.

12. Test diodes D2, D3 and D4 for proper operation using the same procedure described in Step 11.

13. Reconnect all leads and molex plugs.

14. If this test did not identify the problem or to further test the SCRs, go to the Active

SCR Test.

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IDEALARC CV-400

F-24 F-24

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

This test will help determine if the device can be gated ON and conduct current from anode to cathode.

MATERIALS NEEDED

An SCR tester as specified in this procedure. 5/16” Nut driver 9/16” Wrench IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this manual.)

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IDEALARC CV-400

F-25 F-25

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST (continued)

FIGURE F.12 – CONTROL BOARD PLUG

P1 AND P3 LOCATIONS

G2629-[ ] CV-400/CV-500-I CONTROL

#203

Plug P3

#202

FIGURE F.14 – RESISTOR R2 LOCATION

#204 #201

Plug P1

FIGURE F.13 – SNUBBER BOARD

PLUG P5 LOCATION

Plug P5

M15370-[ ] SNUBBER

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TEST PROCEDURE

1. Disconnect the main input supply power to the machine.

2. With the 5/16” nut driver, remove the case top and sides. Remove the screws holding the front panel and lower the panel.

3. Disconnect the welding cables from the welding output terminals.

4. Locate and remove molex plug P3 from the control board. See Figure F.12.

IDEALARC CV-400

5. Locate and remove molex plug P5 from the snubber board. See Figure F.13.

6. Locate and remove lead #204 from resistor R2 (7.5 ohms, 100 Watts). See Figure F.14.

7. Using 9/16” wrench, remove the positive capacitor strap lead and small lead terminal from the positive rectifier plate and output shunt junction. See Figure F.10.

F-26 F-26

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST (continued)

FIGURE F.15 – HEAT SINK TEST POINTS

SCR ANODE

REMOVE ANY INSULA TING P AINT

8. Remove any red insulating paint from the heat sink test points. See Figure F.15.

NOTE: Do not disassemble the heat sinks.

CATHODE (SCR)

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IDEALARC CV-400

F-27 F-27

TROUBLESHOOTING & REPAIR

ACTIVE SCR TEST (continued)

FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS

9. Construct the circuit shown in Figure F.16. One 6-volt lantern battery can be used., Set voltmeter scale low, at approximately 0-5 volts or 0-10 volts.

10. Test the voltage level of the battery. Short leads (A) and (C). Close switch SW-1. Battery voltage should be 4.5 volts or higher. If lower, replace the battery.

11. Connect the tester to the SCR 1 as shown in Figure F.16.

a. Connect tester lead (A) to the anode. b. Connect tester lead (C) to the cathode. c. Connect tester lead (G) to the gate.

12. Close switch SW-1. NOTE: Switch SW-2 should be open.

13. Read meter for zero voltage. a. If the voltage reading is higher than zero,

the SCR is shorted.

14. Close or keep closed switch SW-1.

15. Close switch SW-2 for 2 seconds. Release and read meter.

a. If the voltage is 3-6 volts while the switch

is closed and after the switch is open, the SCR is functioning.

NOTE: Be sure the battery is functioning properly. A low battery can affect the results of the test. Repeat Battery Test Procedure in Step 10 if needed.

16. Open switch SW-1.

17. Reconnect the tester leads. See Figure F.16. a. Connect tester lead (A) to the cathode. b. Connect tester lead (C) to the anode. c. Disconnect test lead (G) from the gate.

18. Close switch SW-1.

19. Read meter for zero voltage. a. If the voltage is zero, the SCR is func-

tioning.

b. If the voltage is higher than zero, the

SCR is shorted.

20. Perform the Active Test Procedure outlined in Steps 11-19 for SCRs 2 and 3.

21. Replace all SCR assemblies that do not pass the above tests.

22. Replace all molex plugs onto the control board and snubber board. Reconnect positive capacitor lead and small lead terminal.

23. Reconnect lead #204 to resistor R2.

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b. If the voltage is 3-6 volts only when the

switch is closed or if there is no voltage when the switch is closed, the SCR is defective.

IDEALARC CV-400

F-28 F-28

TROUBLESHOOTING & REPAIR

NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM

MAXIMUM OUTPUT SETTING – NO LOAD

CH1

0 volts

20 volts

Note: Scope probes connected at machine output terminals: (+) probe to positive terminal, (-) probe to negative terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....2 ms/Div.

Coupling ............................DC

Trigger .........................Internal

2 ms

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IDEALARC CV-400

F-29 F-29

TROUBLESHOOTING & REPAIR

TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED

CH1

0 volts

20 volts

This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank. The CV-400 meters read 400 amps at 36 VDC.

Note: Scope probes connected at machine output terminals: (+) probe to positive terminal, (-) probe to negative terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

5 ms

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IDEALARC CV-400

F-30 F-30

TROUBLESHOOTING & REPAIR

TYPICAL SCR GATE VOLTAGE WAVEFORM

MAXIMUM OUTPUT SETTING – NO LOAD

CH1

0 volts

2 volts

This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operating properly. Note that each vertical division represents 2 volts and that each horizontal division represents 5 milliseconds in time.

Note: Scope probes connected at SCR gate and cathode: (+) probe to gate, (-) probe to cathode.

SCOPE SETTINGS

Volts/Div.......................2V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

5 ms

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IDEALARC CV-400

F-31 F-31

TROUBLESHOOTING & REPAIR

ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED

ONE OUTPUT SCR NOT FUNCTIONING

CH1

0 volts

20 volts

This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “ripple” in the waveform. One SCR gate is disconnected to simulate an open or non-functioning output SCR. Each vertical division represents 20 volts and each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank. The CV-400 meters read 400 amps at 36 VDC.

Note: Scope probes connected at machine output terminals: (+) probe to positive terminal, (-) probe to negative terminal.

SCOPE SETTINGS

Volts/Div.....................20V/Div.

Horizontal Sweep.....5 ms/Div.

Coupling ............................DC

Trigger .........................Internal

5 ms

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IDEALARC CV-400

F-32 F-32

TROUBLESHOOTING & REPAIR

INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in inspecting, cleaning, and replacing the input contactor.

MATERIALS NEEDED

Phillips head screwdriver 5/16” Socket wrench Flat head screw driver 7/16” Socket wrench Low pressure air source

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IDEALARC CV-400

F-33 F-33

TROUBLESHOOTING & REPAIR

INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued)

FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL

1. INPUT SUPPLY LINE

2. INPUT CONTACTOR CR1

3. RECONNECT PANEL

CLEANING PROCEDURE

1. Remove the main input supply power to the machine and remove the input access panel.

2. Locate and get access to the input contactor (CR1) in the input box. See Figure F.17.

3. Remove the input contactor cover plate using a phillips head screwdriver.

WARNING

Do not apply input power to the machine with the input contactor cover plate removed.

4. Blow out any dirt or dust in or around the contacts with a low pressure air stream.

5. Inspect the contacts for signs of excessive wear, pitting, or contacts fused (stuck) together.

a. If any of these conditions are present,

replace the input contactor assembly.

6. Replace the input contactor cover plate.

CONTACTOR REPLACEMENT PROCEDURE

1. Disconnect main input supply power to the machine.

2. Locate and get access to the input contactor (CR1) in the input box. See Figure F.17.

3. Disconnect the main input supply power leads L1, L2, and L3 to the input contactor.

Remove the control transformer primary leads H1, H2 or H3 (dependent on input voltage) from L1 and L3 terminals on the input side of the contactor.

4. Using the 7/16” socket wrench, disconnect the output leads T1, T2, and T3 from the input contactor. (Label the leads.)

5. Identify and label the leads connected to the input contactor coil. See the Wiring Diagram.

6. Disconnect the leads from the input contactor coil (leads X1, #232 and #233). See the Wiring Diagram.

7. Remove the three self-tapping mounting screws using a 5/16” socket wrench. See Figure F.17.

8. Remove the input contactor.

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9. Insert the replacement input contactor and install it following the procedures in reverse order.

NOTE: Be sure to reconnect all leads correctly.

IDEALARC CV-400

F-34 F-34

TROUBLESHOOTING & REPAIR

FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in gaining access to the fan blade and fan motor for maintenance or replacement.

MATERIALS NEEDED

5/16” Nut driver 3/8” Wrench Allen head type wrench

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IDEALARC CV-400

F-35 F-35

TROUBLESHOOTING & REPAIR

FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued)

FIGURE F.18 – FAN MOTOR MOUNTING DETAILS

PROCEDURE

1. Remove the main input supply power to the machine.

2. Using the 5/16” nut driver, remove the case top and sides.

3. The fan blade can be removed using the Allen head wrench.

NOTE: You may need to loosen the machine case back to gain clearance to remove the fan. See Figure F.18.

4. If the fan motor is to be removed, the leads to the motor must be disconnected. This will require cutting the wires or “breaking the splice.”

5. Remove the four mounting nuts and associated flat and lock washers that hold the motor to the mounting bracket. See Figure F.18.

6. Carefully remove the fan motor.

7. To replace the fan motor, mount the motor to its mounting bracket using the four nut and associated flat and lock washers.

8. Resplice any motor leads cut for removal. Soldering the wires is recommended.

9. Reattach the fan blade, if it was removed earlier, using the Allen head wrench to tighten it to the motor shaft.

10. Install the case top and sides.

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IDEALARC CV-400

F-36 F-36

TROUBLESHOOTING & REPAIR

SCR/DIODE RECTIFIER ASSEMBLY

REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in the removal and replacement of the SCR/ diode assembly.

MATERIALS NEEDED

5/16” Nut driver 7/16” Wrench 1/2” Wrench 9/16” Wrench 3/8” Wrench Slot head screw driver 1/2” Socket and extension

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IDEALARC CV-400

F-37 F-37

TROUBLESHOOTING & REPAIR

SCR/DIODE RECTIFIER ASSEMBLY

REMOVAL AND REPLACEMENT (continued)

FIGURE F.19 – SCR/DIODE ASSEMBLY DETAILS

PROCEDURE

1. Remove the main input supply power to the machine.

2. With the 5/16” nut driver, remove the case top and sides.

3. Remove the glastic stiffeners (one on right

side-two on left side). See Figure F.19.

4. Remove lead #220 from the right side of the

negative heat sink plate.

5. Remove the positive capacitor lead and

shunt from the positive heat sink plate. See Figure F.19.

6. Remove the choke and negative capacitor

leads from the left side of the negative heat sink plate. See Figure F.19.

7. Remove the gate leads from the control

board (plug P3).

8. Remove plug P5 from the snubber board.

Also remove lead #224 from the positive output lead. Remove lead #225 from the negative output lead. Remove the green ground lead from the front panel.

Remove the three heavy aluminum secondary leads from the SCR finned heat sinks.

10. Remove the four nuts and associated washers that hold the SCR/diode assembly to the mounting brackets.

11. Carefully lift and remove the SCR/diode heat sink assembly from the machine. Note: It may be necessary to loosen the four sheet metal screws that hold the front panel to the base. Carefully lift and pull out the front panel to allow clearance for SCR/diode

assembly removal. Clear any necessary leads that might hinder removal.

12. For reassembly, carefully place the SCR/ diode assembly into position on the mounting bracket and reinstall the washers and nuts. Tighten the front panel to base if it was loosened earlier.

13. Replace and tighten the four nuts and lockwashers that hold the SCR/diode assembly to the mounting brackets.

14. Reattach the three heavy aluminum secondary leads to the SCR finned heat sinks. Apply a thin coating of Dow Corning 340 heat sink compound (Lincoln E1868) to connection points.

15. Connect the green ground lead to the front panel, lead #225 to the negative output lead, and lead #224 to the positive output lead.

16. Connect plug P5 to the snubber board and plug P3 to the control board.

17. Connect the choke and negative capacitor lead to the left side of the negative heat sink plate. See Figure F.19. Apply a thin coating of Dow Corning 340 heat sink compound (Lincoln E1868) to connection points.

18. Connect the positive capacitor lead and shunt to the positive heat sink plate. See Figure F.19.

19. Install the glastic stiffeners to the left and

right sides. See Figure F.19. Apply a thin coating of Dow Corning 340 heat sink compound (Lincoln E1868) to connection points.

20. Install the case top and sides.

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IDEALARC CV-400

F-38 F-38

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the SCRs from the output rectifier heat sink for maintenance or replacement.

MATERIALS NEEDED

NO.000 Fine Steel Wool Penetrox A-13 (Lincoln E2529) or Penetrox A 7/16” Open end wrench Allen head type wrenches

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IDEALARC CV-400

F-39 F-39

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)

FIGURE F.20 – SCR DETAILS

SPECIAL INSTRUCTIONS

NOTE: Before disassembling the existing rectifier, note toward which heat sink the outer metal ring of the power SCR is mounted. Also, note the positioning of the gate lead of the SCR. Failure to reinstall the new SCR in the same orientation as the original may result in subsequent damage to the new SCR and other components of the welder. See Figure F.20.

CAUTION

The unclamping and clamping procedure outlined below is critical for the prevention of internal SCR damage. Failure to follow this procedure may result in subsequent damage of the SCR. Handle all SCRs with care.

PROCEDURE

1. Remove the main input supply power to the machine.

2. Perform the SCR/Diode Rectifier Assembly Removal and Replacement procedure.

3. Alternately loosen nuts 1/2 turn each until heat sinks are loose. Remove nuts and leaf spring. IT IS RECOMMENDED THAT NEW HARDWARE, LEAF SPRING AND HOUSING BE USED FOR REASSEMBLY.

5. Clean the area on the heat sink around the SCR mounting surface, using a putty knife or similar tool. DO NOT SCRATCH THE SCR MOUNTING SURFACE.

6. Polish each heat sink’s mounting surface using NO. 000 fine steel wool. Wipe surface clean with a lint-free cloth or paper towel.

7. Inspect the mounting surfaces of each new SCR.

a. Remove all burrs and wipe clean. Do

not use steel wool or any abrasive cleanser on the SCR mounting surfaces.

8. Apply a thin (0.001” to 0.003”) layer of PENETROX A-13 (Lincoln Electric #E2529) or PENETROX A, heat sink compound, to each heat sink’s SCR mounting surface.

a. Care must be used to prevent foreign

material contamination of the SCR to heat sink junction.

9. Place the new SCR between the heat sinks. Be sure that the outer metal ring of the SCR is facing toward the same heat sink as the old SCR’s metal ring. Be sure that the roll pin of the heat sink engages the “hole” in the SCR. The SCR contact surfaces must sit flat against both heat sink surfaces.

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4. Remove the old SCR.

IDEALARC CV-400

F-40 F-40

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)

FIGURE F.21 – 1/2” WIDE LEAF SPRING

10. Go to the procedure below that matches your machine’s cap screws. NOTE WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PROCEEDING TO THE ASSEMBLY PROCEDURE. Two different designs of leaf springs and housings have been used to clamp the SCR to the rectifier. The two different designs can be identified by the size of the leaf spring. One design uses a 1/2 inch wide leaf spring, and the other uses a 5/8 inch wide spring. The different designs require different assembly and clamping procedures. The assembly procedure will be different depending upon the thread on the cap screws. A 1/4-28 thread requires a different tightening procedure than a 1/4-20 thread.

FIGURE F.22 – CLAMP ASSEMBLY

PROCEDURE FOR THE 1/2 INCH WIDE SPRING

1. Place a piece of sleeving around each cap screw.

2. Insert cap screws through the leaf spring. Orient the leaf spring so that its ends are curved upward toward the cap screw heads. See Figure F.21. Pressing on the cap screw heads should produce a “rocking” motion of the spring in its housing. If the spring does NOT rock, it is installed upside down. Remove the spring and turn it over. Check for “rocking” motion. See Figure F.21.

3. Insert cap screws and leaf spring into the plastic housing.

4. Insert clamp assembly through heat sinks. Install nuts. Tighten clamp nuts equally on cap screws until finger tight. (See Figure F.22. Heat sinks may not be exactly as pictured.)

5. Reinspect the SCR for proper seating.

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IDEALARC CV-400

F-41 F-41

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)

CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS

NOTE: This procedure can only be used with

1/4-28 cap screws. Do not use cap screws with any other type

thread or new SCR will be damaged. Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

1. Do not turn the nuts. While holding the nuts stationary, turn the cap screws only with the following procedure.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/2 turn.

6. Tighten first cap screw 1/4 turn. Stop.

7. Assembly now has the proper clamping force.

CLAMPING PROCEDURE FOR 1/4-20 CAP SCREWS

NOTE: This procedure can only be used with

1/4-20 cap screws. Do not use cap screws with any other type

thread or new SCR will be damaged. Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

1. Do not turn the nuts. While holding the nuts stationary, turn the cap screws only with the following procedure.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/4 turn. STOP.

6. Assembly now has the proper clamping force.

7. Perform the Active SCR Test.

8. Perform the Active SCR Test.

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IDEALARC CV-400

F-42 F-42

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)

FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING

STEEL PRESSURE PAD

HOUSING

PROCEDURE FOR THE 5/8 INCH WIDE SPRING

1. Place a piece of sleeving around each cap screw.

2. Insert cap screws through the leaf spring. The leaf spring is flat so the orientation of the leaf spring does not matter.

3. Place the steel pressure pad in the housing with the 1/8 inch wide standoff facing up. See Figure F.23.

4. Insert cap screws and leaf spring into plastic housing being sure that the steel pressure pad remains in position. Pressing on the cap screw heads should produce a rocking action of the spring in its housing.

5. Insert the clamp assembly through the heat sinks. Install nuts. Tighten the clamp nuts equally on the cap screws until finger tight. Be sure that the leaf spring is not cocked in the housing. See Figure F.24. Heat sinks may not be exactly as pictured.

FIGURE F.24 – CLAMP ASSEMBLY

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6. Reinspect the SCR for proper seating.

IDEALARC CV-400

F-43 F-43

TROUBLESHOOTING & REPAIR

SCR REMOVAL AND REPLACEMENT (continued)

CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS

NOTE: This procedure can only be used with

1/4-28 cap screws. Do not use cap screws with any other type

thread or new SCR will be damaged. Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

1. Do not turn the nuts. While holding the nuts stationary, turn the cap screws only with the following procedure.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/2 turn.

6. Tighten first cap screw 1/2 turn.

7. Tighten second cap screw 1/4 turn. STOP.

8. Assembly now has the proper clamping force.

CLAMPING PROCEDURE FOR 1/4-20 CAP SCREWS

NOTE: This procedure can only be used with

1/4-20 cap screws. Do not use cap screws with any other type

thread or new SCR will be damaged. Do not over tighten cap screws. The leaf spring

will apply the required clamping force to the SCR.

1. Do not turn the nuts. While holding the nuts stationary, turn the cap screws only with the following procedure.

2. Tighten first cap screw 1/4 turn.

3. Tighten second cap screw 1/2 turn.

4. Tighten first cap screw 1/2 turn.

5. Tighten second cap screw 1/4 turn.

6. Tighten first cap screw 1/8 turn.

7. Tighten second cap screw 1/8 turn. STOP.

8. Assembly now has the proper clamping force.

9. Perform the Active SCR Test.

AFTER REPLACING THE SCRs

Follow the steps in the SCR/Diode Rectifier Removal and Replacement procedure to

reassemble the machine.

9. Perform the Active SCR Test.

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IDEALARC CV-400

F-44 F-44

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES

TO ALUMINUM HEAT SINKS

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in mounting stud type diodes to the aluminum heat sinks on the DC-400.

MATERIALS NEEDED

5/16” Nut driver 1/2” Open end wrench Lincoln E1868 (Dow Corning 340) Heat Sink Compound “Slip” type torque wrench No. 000 fine steel wool

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IDEALARC CV-400

F-45 F-45

TROUBLESHOOTING & REPAIR

MOUNTING OF STUD TYPE DIODES

TO ALUMINUM HEAT SINKS (continued)

PROCEDURE

1. Remove the main input supply power to the machine.

2. With the 5/16” nut driver, remove the case top and sides.

3. Loosen the appropriate diode nut and remove the diode that is to be replaced.

4. Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool. DO NOT SCRATCH THE DIODE MOUNTING SURFACE.

5. Polish each heat sink’s mounting surface using No. 000 fine steel wool. Wipe the surface clean with a lint-free cloth or paper towel.

DIODE STUD FOOT- INCH-

SIZE POUNDS POUNDS

3/4-16 25-27 300-324 3/8-24 10±.5 125+0/-5 1/4-28 22-25

6. Inspect the mounting surfaces of each new diode. Remove all burrs and wipe clean. Do not use steel wool or any abrasive cleanser on the diode mounting surface.

7. Apply a thin (0.003” to 0.007”) uniform layer of E1868 (Dow Corning 340) heat sink compound to the heat sink mounting surface.

a. Do not apply compound to the diode

stud or mounting threads.

b. The diode threads must be clean and

free of defects so that the nut can be finger tightened before applying torque. A “slip” type torque wrench must be used to tighten the diode nut.

8. Tighten the diode nuts to the specifications in the following table.

a. Start the nuts for diodes with steel studs

by hand and then torque them according to the following table.

b. Run the nuts for diodes with copper

studs on all the way by hand then torque them according to the following table.

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c. Turn the nuts a minimum of 1/2 turn

more while torquing.

9. Install the case top and sides.

IDEALARC CV-400

F-46 F-46

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the main transformer for maintenance or replacement.

MATERIALS NEEDED

5/16” Nut driver 9/16” Socket wrench 9/16” Box end wrench 1/2” Socket wrench 1/2” Box end wrench 3/8” Nut driver or socket wrench 9/16” Deep well socket wrench

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IDEALARC CV-400

F-47 F-47

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.25 – LIFT BAIL REMOVAL

REMOVAL OF LIFT BAIL

1. Remove the main input supply power to the machine.

2. With the 5/16” nut driver, remove the case top and sides.

3. Remove the two fiber baffles from the left and right sides of the lift bail adjacent to the main transformer. See Figure F.25.

4. Remove the two leads (#220 and #204)

from resistor R2 (7.5 ohms, 100 watts).

5. Remove the positive capacitor strap from the output shunt.

6. Remove the negative capacitor strap from the negative rectifier plate.

7. Remove the sheet metal screw that holds the capacitor bank assembly to the case back. (This should enable the capacitor bank to be removed with the lift bail assembly.)

8. Using the 9/16” socket wrench, remove the four bolts (left and right) mounting the lift bail to the transformer top and bottom irons.

9. Using the 9/16” socket wrench, remove the four bolts, flat washers, and lock washers mounting the lift bail assembly to the base of the machine.

WARNING

The transformer and choke assembly is now loose and free to slide or “tip” on the base of the machine.

10. Remove the lift bail by lifting straight up and clear from the machine.

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IDEALARC CV-400

F-48 F-48

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.26 – CHOKE REMOVAL

CHOKE LEADS

GLASTIC STIFFENERS

REMOVAL OF CHOKE AND TOP IRON ASSEMBLY

BOTTOM "E" IRON

TOP "E" IRON

THRU-BOLTS (4)

1. Remove the three (two left and one right) glastic stiffeners connecting the negative rectifier plate and choke assembly to the main transformer thru-bolts. See Figure F.26.

2. Remove the top choke lead from the negative rectifier plate.

3. Remove the bottom choke lead from the negative output terminal.

4. Using the 9/16” deep well socket wrench, remove the four thru-bolts that clamp the top “E” iron and choke assembly to the bottom “E” iron. NOTE: for easier reassembly, clean the threads.

5. Using a hoist, carefully lift the choke and top iron assembly out and clear of the transformer coils.

NOTE: The coils may be “stuck” to the top iron

and may require some careful prying to dislodge them. Depending upon which coil(s) are to be replaced, it may be advantageous to remove some of the “stuck” coils with the top iron.

6. The leads from the coils that are to be removed and/or replaced must be disconnected. See the Wiring Diagram.

When aluminum leads are re-connected, apply a thin layer of Dow Corning 340 Heat Sink Compound (Lincoln E1868) to mating surfaces.

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IDEALARC CV-400

F-49 F-49

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.27 – EPOXY MIX APPLICATION AREAS

REASSEMBLY OF TRANSFORMER COILS

NOTE: The following procedure describes a

complete replacement of all primary and secondary transformer coils. Adapt the procedure for the specific coils you may be replacing.

1. Apply a coating of Lincoln Electric E2547 Epoxy Mix along both sides of the bottom iron (lamination) assembly in the areas where the coil sides will be mounted. Coat the areas no closer than .38 inches from the top edge of the iron. See Figure F.27, arrows. Be sure that none of the epoxy drips onto the top of the iron assembly where it will meet the top assembly.

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IDEALARC CV-400

F-50 F-50

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.28 – COIL LEAD PLACEMENT

MACHINE FRONT

SECONDARY COIL LEADS

PRIMARY COIL LEADS

3. Install the bottom primary coils, one on each of the three legs of the bottom iron assembly. The coils must be in correct position (left, center, right). Place the coils so that the leads come out at the back of the machine. See Figure F.28 for proper positioning.

4. Place insulation (Lincoln Electric part number S20728) on top of each of the three primary coils. The longer side of the insulation should be placed toward the front of the machine. See Figure F.29 for the location of this insulation

5. Place the three secondary coils on top of the insulation installed in Step 4. The leads should come out at the front of the machine with the short leads on top. See F.28 for proper positioning.

6. Insert shims (Lincoln Electric part number CI001250 or CI000317) between the secondary coil sides and the iron assembly on either side of the legs. See Figure F.29.

FIGURE F.29 – COIL INSULATION

PRIMARY COILS

TOP LEFT

TOP CENTER

7. Place insulation (Lincoln Electric part number S20728) on top of each of the three secondary coils. The longer side of the insulation should be placed toward the front of the machine, where the secondary start and finish leads come out. See Figure F.29.

8. Install the three top primary coils, noting which is right, left, and center. Leads should come out at the back of the machine. See Figure F.28 for proper positioning. The coils must be in correct position (left, center, right).

9. Install the top iron (lamination) and choke assembly. With the 9/16” deep well socket wrench, reassemble the four thru-bolts that clamp the top “E” iron to the bottom “E” iron. Lightly tap on the top of the iron with a hammer before tightening. Tighten the nuts and thru bolts to 19-25 lb-ft.

TOP RIGHT

SECONDARY COIL ASSEMBLY

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INSULATION

PRIMARY COIL (BOTTOM)

SHIMS

IDEALARC CV-400

F-51 F-51

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.30 – PRIMARY THERMOSTAT LOCATION

TOP VIEW

THERMOSTAT

INSULATION

10. Mount the primary thermostat to the lead end coil nose. See Figure F.30. Place a small amount of Lincoln Electric E1603 Epoxy between the coil nose and the coil insulation and between the insulation and the thermostat. Hold the thermostat in place with E2381 (.375” wide) tape. If necessary, after assembly protect the thermostat terminals with E2547 terminal boots.

FIGURE F.31 – SECONDARY LEAD TRIM AND WELD DETAIL

FRONT VIEW

11. If necessary, trim off excess secondary lead stickout and TIG weld the leads together. See Figure F.31.

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TIG WELD

IDEALARC CV-400

F-52 F-52

TROUBLESHOOTING & REPAIR

MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE

NOTE: The following procedure assumes you have

completely reassembled the transformer coils as described in the procedure above. The lower iron has remained in place in the machine. See Figures F.25 and F.26.

1. Attach the bottom choke lead to the negative output terminal.

2. Attach the top choke lead to the negative rectifier plate.

REASSEMBLE THE LIFT BAIL

1. Carefully position the lift bail onto the machine base. Using the 9/16” socket wrench, attach the lift bail to the base of the machine with four bolts, flat washers, and lock washers.

2. Using the 9/16” socket wrench, attach the lift bail to the transformer top and bottom irons with four bolts.

3. Attach the sheet metal screw that holds the capacitor bank assembly to the case back.

4. Connect leads #220 and #204 to resistor R2.

5. Connect the negative capacitor strap to the negative rectifier plate.

6. Connect the positive capacitor strap to the output shunt and positive rectifier plate.

7. Attach the fiber baffle on the bottom choke lead.

8. Attach the two fiber baffles to the left and right sides of the lift bail, adjacent to the main transformer.

9. Install the machine case top and sides. NOTE: When aluminum leads are reconnected,

apply a thin layer of Dow Corning 340 Heat Sink Compound (Lincoln E1868) to the mating surfaces.

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IDEALARC CV-400

F-53 F-53

TROUBLESHOOTING & REPAIR

RETEST AFTER REPAIR

Retest a machine:

• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR

• If you repair or replace any electrical components.

INPUT IDLE AMPS AND WATTS

Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW

200/3/60 10.9 1.2 208/3/60 10.5 1.2 220/3/60 9.9 1.2 230/3/60 9.5 1.2 380/3/60 5.8 1.2 400/3/60 5.5 1.2 415/3/60 5.3 1.2 440/3/60 5.0 1.2 460/3/60 4.8 1.2 500/3/60 4.4 1.2 575/3/60 3.8 1.2

200/3/50 19.8 1.2 220/3/50 18.0 1.2 230/3/50 17.2 1.2 380/3/50 10.4 1.2 400/3/50 9.9 1.2 415/3/50 9.5 1.2 440/3/50 9.0 1.2 500/3/50 7.9 1.2

OPEN CIRCUIT VOLTAGES

Test Points Input Hertz Open Circuit Volts

Welding Output Terminals 60 43/47VDC

Welding Ouput Terminals 50 43/47VDC

Auxiliary Output (#31 - #32) 60 114/124VAC Auxiliary Output (#31 - #32) 50 109/119VAC

Auxiliary Output (#41 - #42) 60 43.8/47.5VAC Auxiliary Output (#41 - #42) 50 42.0/45.6VAC

Auxiliary Output (#51 - #52) 50 220/231VAC

Output Control Setting Amps Volts

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

WELDING OUTPUT LOAD TEST

Minimum 75 to 150 6 to 11

Maximum 525 more than 41.2

IDEALARC CV-400

F-54 F-54

NOTES

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IDEALARC CV-400

G-1 G-1

ELECTRICAL DIAGRAMS

Electrical Diagrams Section...........................................................................................................Section G

Wiring Diagram (Codes 10084, 10085, 10086).....................................................................................G-2

Wiring Diagram (Code 10087)...............................................................................................................G-3

Control PC Board (G2629-1) Layout......................................................................................................G-4

Control PC Board (G2629-1) Schematic ...............................................................................................G-5

Snubber PC Board (M15370-3) Layout .................................................................................................G-6

Snubber PC Board (M15370-3) Schematic...........................................................................................G-7

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

IDEALARC CV-400

G-2 G-2

ELECTRICAL DIAGRAMS

Wiring Diagram (Codes 10084, 10085, 10086)

DUAL & SINGLE VOLTAGE UNDER 346 VOLTS (SHOWN CONNECTED

FOR LOW VOLTAGE)

N.B.

232

233

SINGLE VOLTAGE OVER 345 VOLTS

TO GROUND PER NATIONAL ELECTRICAL

CODE

N.B.

232

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.The wiring diagram specific to your

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CONTACTOR

233

SNUBBER

BOARD

.0047MFD

OUTPUT CHOKE

GROUNDING

GREEN

TO SUPPLY

LINES

V U

CR1

TO SUPPLY

LINES

CR1

1 2

2 3

3 4

6 7

7 8

1400V

STUD

3 2

N.A.

TS1

PER NATIONAL

ELECTRICAL CODE

RECONNECT PANEL

220/380/440V AND

220

220 221

221

222

223

223 225

225

224

GREEN

204

225

2 31 32

TS2

76 77

N.F.

TO GROUND

COILS

TO PRIMARY

THIS CONNECTION DOES NOT APPEAR ON

230/400V NACHINES

TOP

PRIMARY

AUXILIARY

COILS

BOTTOM

PRIMARY

RECTIFIER ASSEMBLY

N.A.

2 4

230/400 VOLTAGE (SHOWN CONNECTED

FOR 230 V.)

N.B.

232

CIRCUIT

BREAKER

201

SEC

CONTACTOR

233

220V

21V

TO SUPPLY

LINES

CR1

T0 PRIMARY COILS

N.E.

RECONNECT PANEL

TO GROUND

PER NATIONAL

ELECTRICAL CODE

115V

SEC

FAN MOTOR 115V

202

21V

204

380/500 V.

(SHOWN CONNECTED

FOR 380 V.)

TO SUPPLY

N.B.

232

CR1

CONTACTOR

233

42A

42V

203

203 21V

SEC

LINES

3 2

10AMP

CIRCUIT

BREAKER

SECONDARY THERMOSTAT

T1 MAIN

TRANSFORMER

TO GROUND

PER NATIONAL

ELECTRICAL CODE

RECONNECT PANEL

TO PRIMARY

COILS

16 17 18

N.A.

220 220

204

SHUNT

205

206 212

220

205 206

213

N.C.

DIODE

OPTION

LEAD NOT PRESENT

206

WITH DIODE OPTION

233

POWER

SWITCH

224

VOLTMETER

SWITCH

206

225

10A CIRCUIT BREAKER

212 210

OUTPUT CONTROL

205

METERS

OPTIONAL

206

SWITCH

N.D.

32A

SCR2

SCR3

202

204 203

201

SCR2

G3 G2

G2 G1

7 8

CONTROL BOARD

204

CONTROL BOARD

GROUNDING LEAD

SCR1

240

211

213

210

10K /2W

OUTPUT

CONTROL

LIGHT

232

PILOT LIGHT

211

THERMAL

PROTECTION

225

code is pasted inside one of the enclosure panels of your machine.

IDEALARC CV-400

241

THERMOSTAT

231

N.B.

233

232

32A

PRIMARY

CAPACITOR

DISCHARGE

OPTION

TO SUPPLY

LINES

W V U

CR1

CONTACTOR

224

220/380/440 VOLTAGE

(SHOWN CONNECTED FOR 220 V.)

RECONNECT PANEL

3 2

CONNECT OR

CONNECT OR INSULATE AS

INSULATE AS SHOWN ON

SHOWN ON INPUT

INPUT CONNECTION

CONNECTION DIAGRAM

DIAGRAM

T2 CONTROL

TRANSFORMER

231

4 41

CR4

10A

SLOW

BLOW

204

254

204

220

ELECTRICAL SYMBOLS PER

4 PIN 8 PIN

J3 J2

CONNECTOR CAVITY

CONNECTOR CAVITY NUMBERING SEQUENCE

NUMBERING SEQUENCE (COMPONENT SIDE OF P.C.

(COMPONENT SIDE OF P.C. BOARD)

BOARD)

NOTES

N.A. CIRCUITRY PRESENT ON

CAPACITOR DISCHARGE

N.B. TAPE UP SEPARATELY

TO PROVIDE AT LEAST

600 V INSULATION.

N.C. CIRCUITRY PRESENT ON

DIODE OPTION ONLY.

N.D. THESE LEADS ARE PRESENT

WITH METER OPTION ONLY.

N.E. 220V WINDING, PLUG

AND CIRCUIT BREAKER

ARE PRESENT ONLY

ON CV500-I.

N.F. 31 AND 32 ARE NOT

PRESENT ON EUROPEAN CV500-I

12-9-94F

L9269

TO PRIMARY COILS

H2 H3

H3 H4

CAPACITOR

CAPACITOR DISCHARGE

DISCHARGE

RELAY

0.5 /50W

31,000MFD

31,000MFD 50V EACH

50V EACH

7.5 /100W

TO GROUND

PER NATIONAL

ELECTRICAL

CODE

FLEX LEAD

JUMPER

115V

231

E1537

J5J1

ONLY.

G-3 G-3

ELECTRICAL DIAGRAMS

Wiring Diagram (Code 10087)

230/460/575V.

(SHOWN CONNECTED FOR 230 V.)

N.B.

TO SUPPLY

LINES

TO GROUND PER NATIONAL

ELECTRICAL CODE

FAN MOTOR

T1 MAIN

TRANSFORMER

AUXILIARY

COILS

TOP

PRIMARY

BOTTOM

PRIMARY

220

1 2

221

222

223

5 6

6 7

7 8

SNUBBER

BOARD

225

N.A.

.0047MFD

1400V

L1 OUTPUT CHOKE

STUD

TS2

TS1

223

225

224

GREEN

204

GROUNDING

GREEN

201

2 31 32

76 77

2 4

RECTIFIER

ASSEMBLY

N.A.

X1 SEC

224

VOLTMETER

SWITCH

225

21V

OUTPUT CONTROL

205

206

METERS

OPTIONAL

206

10A

CIRCUIT

BREAKER

212 210

X2 SEC

220 220

SCR1

201

202

204

203

240

32A

211

213

SWITCH

N.D.

225

115V

202

21V

SCR2

4 5

6 7 8

CONTROL BOARD

10K /2W

CONTROL

204

210

OUTPUT

SCR3

G3 G2

G2 G1

211

PROTECTION

240

THERMAL

LIGHT

42V

X3 SEC

42A

203

21V

204

10AMP CIRCUIT BREAKER

SECONDARY

THERMOSTAT

204

SHUNT

206

205

204

205

206

212

220

205

206

213

7 8

CONTROL BOARD

GROUNDING LEAD

232

233

PILOT LIGHT

N.A.

N.C.

DIODE

OPTION

LEAD NOT PRESENT WITH DIODE OPTION

233

POWER

SWITCH

241

231

32A

PRIMARY

THERMOSTAT

CAPACITOR

DISCHARGE

OPTION

233

224

CONTACTOR

232

L2L3

W V

CR1

4 41

RECONNECT PANEL

CONNECT OR INSULATE AS SHOWN ON INPUT CONNECTION

DIAGRAM

231

CR4

10A SLOW BLOW

3 9

7 1

H2 H3

T2 CONTROL

TRANSFORMER

204

254

+ 204

220

7.5 /100W

ELECTRICAL SYMBOLS PER E1537

4 PIN 8 PIN

4 PIN

CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD)

NOTES

N.A.

CIRCUITRY PRESENT ON CAPACITOR DISCHARGE ONLY.

N.B. TAPE UP SEPARATELY

TO PROVIDE AT LEAST

600 V INSULATION.

N.C. CIRCUIT PRESENT ON

DIODE OPTION ONLY.

N.D. THESE LEADS ARE

PRESENT WITH METER

OPTION ONLY.

12-9-94F

L9270

16 17 18

TO PRIMARY

115V

CAPACITOR DISCHARGE

RELAY

0.5 /50W

31,000 MFD 50V EACH

J1,

J2 &

N.B.

COILS

231

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.The wiring diagram specific to your

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

code is pasted inside one of the enclosure panels of your machine.

IDEALARC CV-400

G-4 G-4

ELECTRICAL DIAGRAMS

Control PC Board (G2629-1) Layout

D50

D79

C20

R99

R95

R83

R98

R193

R192

D40

R191 R190

R82 C19

D51

D31

D52

R124 D33 D32

D42

D41 R158 R159 R157 R156

C45

R81

ITEM

R151

D48

R26

D49

D10 D13 D16

R160

C10

R163 D65

D11 D14 D17

R113

R161

C11

R164 D66

D12 D15 D18

D67

R114

R162

D71

C12

R165

QU1

C7 R17 R29

SCR1

R14

R11

R10

R20

DZ1

R166

R169

R27

QU2

C8 R18 R30

SCR2

R15

R12

R86

R21

DZ2

R167

R170

R28

QU3

C9 R19 R31

SCR3

R16

R13

R87

R22

DZ3

R168

R171

G2629-1 CV400 / CV500-I CONTROL

C23

C35

R143

R60

R76

R51 R50

C17 R77

R79

D23

R145

R146

D80

C46

R90

D47

D37

R93

C15

R61

R94

R91

R57

R62

R176

C22

R175

R154

C30

C24

R56 R39

R35

R37 R36 R43

C38 C37

C18

R78

R135

R142

D55

R70 R75

D35

D34

R140

R89

R88

R137

R134

R139

C36

D63

C31

D62

D83

R115

R58

R59

R153

R155

OCI1

R152

DZ12

DZ13

D76

D78

D22

D75

D77

R38

R71

R183

R184

R185

R186

R187

R188

R189

R141

C39

DZ10

DZ9

C41

C44

R40

R41

R144

R149

D74

DZ5

R63

R64

R112

R148

C40

D81

C43

R150

DZ14

D72

D82

D19

D20

R172

R173

R174

R177

R178

R179

R180

R181

R182

D73

D68

D69

D70

D21

REQ’D.

PART No.

IDENTIFICATION

J1 J2 J3

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

your factory warranty. Individual Printed Circuit Board Components are not available from Lincoln Electric.This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

IDEALARC CV-400

G-5 G-5

ELECTRICAL DIAGRAMS

Control PC Board (G2629-1) Schematic

9148

LM224

-10V

LM224

2.21K

R50

MIN. OUTPUT

BUFFER

-10V

204

C30

C31

-10V

R51

100K

267

R76

D32

D33

C17

R79

FIRING CIRCUIT

60V

DZ5

15V

243

R174

160

D81

R177 R178 R179 R180 R181 R182 R183 R184 R185 R186 R187 R188 R189

D77

D76

6.2V

DZ12

100K

10K

MAX. OUTPUT

BUFFER

100

+15V

D34

4.7

35V

2.67K D6

200V

.15

4.75K

R19

200

R171

100K

R31

240

243

R173

243

R172

D82

R177-R189=68.1K 1/4W

1.5K

R150

R149

15W

D75

DZ13

15V

100

R152

CNY17-3

OCI1

+15V

R115

1.82K

-10V

R82

4.75K

DZ3

15V

2.67K

R13

100K

2N6027

QU3

267

R16

50K

R28

562

R162

R165

562

C12

24V

DZ14

1.5K

15W

D52

C19

R168

267

OUTPUT

PILOT

CIRCUIT

R81

212

R197

R198

R199

R87

475

R22

1.00K

R60

75.0

400V

METERS

205

R61

D67

R114

SCR3

D12

6J22

100V

.047

C37

475

CURRENT

AMP

43.2K

+15V

R176

10K

221K

PRESET

START

R94

15.0K

20V

1.8

R93

206

R58

C20

200

10V

20V

2.21K

D50

R64

15V

DZ10

50K

R38

TRIM

D37

OFFSET

D55

C15

1.8

+15V

R83

10K

2.67K

R12

2N6027

QU2

R27

562

R161

R164

562

-10V

SUPPLY

10W

250

R148

150

50V

+15V

CURRENT

AMP

100K

R57

D51

10K

R139

+15V

DZ2

100K

267

R15

R167

50K

C11

C43

R59

D79

50V

15.0K

267

D71

600V

D72

600V

D73

600V

2.70

R40

2.5W

100K

CURRENT

SWITCH

2.67K

R154

+15V

0.1

C46

D48

75.0

R194

75.0

R195

R196

R86

475

400V

R21

1.00K

600V

C40

150

50V

GND

17V

DZ9

4.7

35V

C41

+15V

D47

475K

CONTROL

R113

D66

SCR2

D14

D11

D17

D68

D69

D70

2.70

R41

2.5W

D74

OUT

+15V

SUPPLY

.15

C23

100V

R89

33.2K

R88

221K

R135

100K

R137

C36

4.7

35V

202

35V

4.7

2.67K D4

200V

.15

4.75K

R17

200

R169

100K

R29

.047

100V

C38

R43

150

R35

150

R36

-10V

R37

221K

R39

100K

R56

R124

10K

D31

4.7

35V

C24

CURRENT

LIMITER

R62

D83

R90

15.0K

R91

10K

100K

R175

C22

4.75K

203

20V

1.8

1.00K

D49

R63

35V

4.7

2.67K D5

200V

.15

4.75K

R18

R170

100K

R30

204

2.21K

1.00K

75.0

D15 D18

15V

D23

R143

.33

50V

15.0K

2N4857

2N6027

QU1

202

203

201

10K

R144

35V

C39

D22

10K

R145

10K

C35

R134

2.67K

R11

50K

R26

562

R160

R163

562

C10

R142

10K

221K

R155

D80

2.67K

R146

13.7K

1.50K

R159

-10V

D63

DZ1

100K

R157

1.50K

R158

-10V

D41

22.1K

R95

R190

1.00K

4.32K

R191

D40

75.0

R10

475

400V

267

R20

R14

1.00K

R166

267

D13

D16

10W

R151

+15V

D78

C44

4.7

35V

R153

D62

12.1K

R71

R70

+15V

R75

D35

-10V

+15V

C18

R77

1.50K

R78

213

15A

DGS

203L202

201

D21

D19

D20

600V

+15V

R141

OUTPUT CLAMP

POWER UP

R156

13.7K

VOLTAGE BUFFER

1400V

.0047

C45

D42

+15V

TL431

REF

10K

R98

PROTECTION

OVER-VOLTAGE

475K

R99

201

R112

D65

SCR1

D10

9148

7-18-97J

R140

10K

220

RECTIFIER BRIDGE

R193

1.82K

2.00K

R192

CAPACITOR

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IDEALARC CV-400

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting.PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board

Components are not available from Lincoln Electric.This information is provided for reference only.Lincoln Electric discourages board level troubleshooting and repair since it may com-

promise the quality of the design and may result in danger to the Machine Operator or Technician.Improper PC board repairs could result in damage to the machine.

G-6 G-6

ELECTRICAL DIAGRAMS

Snubber PC Board (M15370-3) Layout

M15370-3

TP3 TP1

TP6

TP2

TP5

TP4

SNUBBER

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

ITEM

C1,C2,C3

C4,C5

R1,R2,R3 TP1,TP2,TP3 TP4,TP5 TP6

REQD

3 2

3 3 2

PART NO.

T11577-68 T11577-46

T12733-10 T13640-12 T13640-18

T13640-16

DESCRIPTION

.68/400

.05/600

10 2W

38J

160J

80J

IDEALARC CV-400

Lincoln Electric SVM136-A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY

Major physical or electrical damage is evident when the sheet metal cover(s) are removed.

Machine is dead - no output - no fan - no pilot light.

The input contactor operates - the fan runs - the pilot light is on - but the machine has no welding output.

The input contactor (CR1) chatters.

The machine has minimum (or very low) welding output and no control.

The machine will not shut off when the power switch is put in the OFF position.

The output terminals are always electrically “hot.”

Poor arc characteristics. 1. Make sure the correct weld pro-

The welding arc is variable and sluggish.