Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Soudage A L...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - TABLE OF CONTENTS; Page
vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Select Suitable Location ..........
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – IDEALARC CV-400-I; DC; INPUT - THREE PHASE ONLY
A-1 CV-400-I A-1 INSTALLATION TECHNICAL SPECIFICATIONS – IDEALARC CV-400-I Code Number 10183 (Export, NEMA Rated) 10182 (European, IEC Rated) 10184 (Export, NEMA Rated) 10185 (Export, NEMA Rated) 10186 (Export, NEMA Rated) Volts at Rated Amperes 3632 3429 Auxiliary Power 42 Volts AC, 10 Amps 115 Vol...
Page 9 - SAFETY PRECAUTIONS; STACKING; INPUT CONNECTIONS; circuit breakers may be used in place of; ELECTRIC SHOCK can kill.; RECOMMENDED INPUT WIRE AND FUSE SIZES
A-2 INSTALLATION CV-400-I A-2 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS SELECT SUITABLE LOCATION Place the welder where clean cooling air can freelycirculate in through the side louvers and out throughthe rear louvers. Dirt, dust or any foreign material thatcan...
Page 10 - FIELD INSTALLED OPTIONS; Cable Sizes for Combined Lengths of Copper
A-3 INSTALLATION CV-400-I A-3 FIELD INSTALLED OPTIONS For installation of compatible field installed options(see the ACCESSORIES section of this manual andrefer to the instructions included with those options. REQUIRED EQUIPMENT-CONTROLCABLE CONNECTIONS Follow the instructions below which are approp...
Page 11 - PARALLELING; NOTE: If you intend to use a standard Lincoln wire
A-4 INSTALLATION CV-400-I A-4 PARALLELING The CV-400-I is not designed to be paralleled with anyother power source. CONNECTION OF AUXILIARY EQUIPMENTTO THE WIRE FEEDER RECEPTACLE Occasionally, it may be necessary to make connectionto the circuits present in the 14-pin wire feeder recep-tacle. These ...
Page 12 - OPERATION; OPERATING INSTRUCTIONS; GENERAL WARNINGS
B-1 OPERATION B-1 CV-400-I ELECTRIC SHOCKcan kill. • Do not touch electrically live parts or electrode with skin or wetclothing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASEScan be dangerous. • Keep your head out of fumes. • Use ventilation or exhaust...
Page 13 - GENERAL DESCRIPTION; CAUTION
B-2 OPERATION B-2 When using a CV-400-I power source with wire feeders,there will be a small spark if the electrode contacts the workor ground within several seconds after releasing the trigger. When used with some wire feeders with the electrical triggerinterlock in the ON position, the arc might r...
Page 14 - CONTROLS AND SETTINGS
B-3 OPERATION B-3 A. POWER SWITCH - A two-position toggle switch.Controls the input power to the CV-400-I. B. VOLTAGE ADJUST - Controls the CV-400-I output voltage. C. THERMAL PROTECTION INDICATION LIGHT - Indicates that the protection thermostat has activated. The digital meter will display "E1...
Page 16 - -The low inductance connection is typically; OUTPUT PANEL CONNECTIONS
B-5 OPERATION B-5 CV-400-I A., B., C. OUTPUT CONNECTORS -Each connector is a Magnum Twist-Mate™, r e c e p t a c l e . I n s e r t a m a t i n g T w i s t - M a t e ™plug, and twist clockwise to secure. F o r G M A W p r o c e s s e s , a n d m o s t F C A Wprocesses, the positive output connectiong...
Page 17 - CASE BACK CONNECTIONS
B-6 OPERATION B-6 CV-400-I A. 220 VAC RECEPTACLE Continental European type, nonpolarized, ground-ed receptacle (also known as a "Schuko" type) forconnection of water coolers or other equipment. B. CIRCUIT BREAKER Protects the 220 volt auxiliary circuit from over- loads and shorts. If this br...
Page 18 - STARTING THE MACHINE; NOTE: The arc voltage at the electrode may be as much as; LOCAL/REMOTE SWITCH OPERATION; NOTE: Do not use circuits 2 or 4 for control of auxil-; OVERLOAD PROTECTION
B-7 OPERATION B-7 STARTING THE MACHINE The power switch at the extreme right side of the con-trol panel energizes the CV-400-I. ADJUSTING THE OUTPUT VOLTAGEUSING THE DIGITAL METER The digital meters in the CV-400-I incorporate a voltage pre-set function. This allows the operator to set the desiredwe...
Page 19 - ACCESSORIES
C-1 ACCESSORIES C-1 FACTORY INSTALLEDOPTIONS/ACCESSORIES There are no factory installed options/accessories onthe CV-400-I. FIELD INSTALLED OPTIONS REMOTE VOLTAGE CONTROL (K857) The K857 consists of a control box with 25 feet (7.6m) of four conductor cable. Installation of a K857Remote Voltage Contr...
Page 20 - MAINTENANCE; GENERAL MAINTENANCE; The fan motor has sealed bearings which require; MACHINE AND CIRCUIT PROTECTION
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS GENERAL MAINTENANCE 1. The fan motor has sealed bearings which require no service. 2. In extremely dusty locations, dirt may clog the air channels causing the welder to run hot with prema-ture tripping of thermal protection. Blow out thewelder with low pressure...
Page 21 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE; LOCAL AUTHORIZED LINCOLN ELECTRIC; for assistance before you proceed.
E-1 TROUBLESHOOTING E-1 CV-400-I This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-l e m s w i t h m a c h i n e s e t u p o r o p e r a t i o n .S i m p l y f o l l o w t h e t h r e e - s t e p p r o c e d u r e listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look u...
Page 22 - Local Lincoln Authorized Field Service Facility; ERROR; BUILT-IN DIAGNOSTIC ROUTINES AND ERROR CODES
E-2 TROUBLESHOOTING E-2 CV-400-I Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting ass...
Page 23 - PROBLEMS; MACHINE TROUBLESHOOTING GUIDE
E-3 TROUBLESHOOTING E-3 CV-400-I Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting ass...
Page 26 - for technical troubleshooting assistance before you proceed.; Observe all Safety Guidelines detailed throughout this manual; Leads or connections open in; OPTIONS TROUBLESHOOTING GUIDE
E-6 TROUBLESHOOTING E-6 CV-400-I If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION Observe all Safety Guideli...
Page 27 - Procedure for Replacing PC Boards; CONTROL PC BOARD
E-7 TROUBLESHOOTING E-7 CV-400-I If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION Procedure for Replacing PC...
Page 29 - DIAGRAMS
F-1 DIAGRAMS F-1 CV-400-I CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P. C. BOARD) ELECTRICAL SYMBOLS PER E1537 + - L1 SECONDARY THERMOSTAT 222 223 224 D4 C1 C2 C3 C4 + + + + R1 SCR2 D2 D5 222 204A 204D CONTROL P. C. BOARD 221 6 PIN 4 PIN 8 PIN SNUBBER/BYPASS P.C. BOARD 224 22 4A 224A 10A...
Page 31 - CV POWER SOURCE TO AN LN-7 AND K857
F-3 DIAGRAMS F-3 CV-400-I CV POWER SOURCE TO AN LN-7 AND K857 Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDI...
Page 32 - CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER
F-4 DIAGRAMS F-4 CV-400-I CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. 76 82 81 SPARE 2 4 41 42 31 32 GND 21 77 75 REMOTE OUTPUT CONTROL N.D. 2 4 10K MIN. Only qualified perso...
Page 34 - CV POWER SOURCE TO AN LN-25
F-6 DIAGRAMS F-6 CV-400-I CV POWER SOURCE TO AN LN-25 Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE...
Page 36 - LINCOLN POWER SOURCE TO AN LN-742
F-8 DIAGRAMS F-8 CV-400-I LINCOLN POWER SOURCE TO AN LN-742 Only qualified persons should install, use or service this machine. WARNING ELECTRIC SHOCK CAN KILL ELECTRODE CABLE - + 14 PIN AMPHENOL POWER SOURCE LINCOLN TO WORK LN-742 WIRE FEEDER Power Source before connecting the wire feeder. Turn off...
Page 38 - TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS
F-10 DIAGRAMS F-10 CV-400-I TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS T U R N T H E P O W E R S W I T C H O F T H E W E L D I N G P O W E RS O U R C E " O F F " B E F O R E I N S T A L L I N G P L U G S O N C A B L E SO R W H E N C O N N E C T I N G O R D I S C O N N E C T I N G P L U ...
Page 39 - CONNECTION OF NON-LINCOLN WIRE FEEDERS
F-11 DIAGRAMS F-11 CV-400-I CONNECTION OF NON-LINCOLN WIRE FEEDERS
Page 40 - DIMENSION PRINT
F-12 DIAGRAMS F-12 CV-400-I DIMENSION PRINT 5-18-90J N.A. N.A. N.A. N.A. FOUR SLOTS IN BASE FOR MOUNTING WELDER DOWN USING 5/16 SCREWS 1.68 N.B. N.B. HANDLE CONFIGURATION ON EARLIER MODELS. 20.05 (509) 19.65 (499) 19.20 (487) 41.58 (1056) 26.00 (660) 3.61 (91) 12.60 (320) (42.7) 11.99 (304) 3.90 (99...
Page 41 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l...
Page 42 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...