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
View Safety Info View Safety Info View Safety Info View Safety Info
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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
to
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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
RETURN TO MAIN INDEX
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.
2
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
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.
1
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
H3
CR1
W
V
CONTACTOR
U
H1
PILOT
TRANSF.
H2
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.
LINK
L3
LINES
L2
INPUT
{
L1
GND
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
H2
CR1
W
V
CONTACTOR
U
H1
PILOT
TRANSF.
H3
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
21
-
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
2
67 mm
2
50 to 100 ft 3/0 2/0
(15 to 30 m) 85 mm
2
67 mm
2
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100 to 150 ft 3/0 3/0
(30 to 46 m) 85 mm
2
85 mm
150 to 200 ft 3/0 3/0
(46 to 61 m) 85 mm
2
85 mm
200 to 250 ft 4/0 4/0
(67 to 76 m) 107 mm
2
107 mm
IDEALARC CV-400
2
2
2
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
8
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.
9
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
10
11
1
2
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
L
D=4
E=77
M
J=31
I=41
N
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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TO
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
21
4
2
31
32
75
76
77
TERMINAL
STRIPS
21
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
TO
AUTOMATIC
CONTROL
BOX
GND
21
4
2
TERMINAL
STRIPS
21
4
2
BLANK
31
32
31
32
75
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
21
4
2
TERMINAL
STRIPS
21
4
2
BLANK
31
32
31
32
75
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.
TO
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
21
4
2
TERMINAL
STRIPS
21
4
2
BLANK
31
32
31
32
75
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
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