Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
SAFETY i i IDEALARC CV-400 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 eng...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii IDEALARC CV-400 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 m...
Page 4 - iii
IDEALARC CV-400 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...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv IDEALARC CV-400 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vou...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page; RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v IDEALARC CV-400 Page Safety ...............................................................................................................................................i-i-v Installation ...................................................................
Page 7 - TABLE OF CONTENTS; Section A
TABLE OF CONTENTS - INSTALLATION SECTION - Section A-1 Section A-1 IDEALARC CV-400 Installation ............................................................................................................................. Section A Technical Specifications ..............................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - IDEALARC CV-400
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 IDEALARC CV-400 TECHNICAL SPECIFICATIONS - IDEALARC CV-400 INPUT - THREE PHASE ONLY Standard Voltag...
Page 9 - SAFETY PRECAUTIONS; LOCATION AND VENTILATION; LIFTING; FALLING EQUIPMENT can cause injury.; STACKING; ELECTRICAL INPUT CONNECTIONS
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals orinternal wiring. • Insulate yourself from the work and ground. • Turn power switch off before connecting or discon- nectin...
Page 10 - GROUND CONNECTION; cations page for proper ground wire size.; INPUT SUPPLY CONNECTIONS; • Turn the input power off at the; RATING PLATE LOCATION
GROUND CONNECTION The frame of the welder must be grounded. An earthgrounding lead must be connected to the groundingterminal, marked on the input box floor with the symbol (See Figure A.2). Refer to Technical Specifi- cations page for proper ground wire size. INPUT SUPPLY CONNECTIONS Be sure the vo...
Page 11 - Also refer to; Reconnect Procedure later in this section.; INPUT WIRE AND FUSE SIZE; Technical Specifications at the begin-; ning of this section or use delay type; Technical; REAR PANEL
Have a qualified electrician connect the input powerleads to the L1, L2, and L3 terminals of the input con-tactor. Follow all national and local electrical codes.Use a three-phase line. Install the reconnect paneljumper links (see Figure A.3) for the proper input volt-age. See the connection diagram...
Page 12 - See; Table A.1 for recommended cable sizes for com-; bined lengths of electrode and work cables.
RECONNECT PROCEDURE Multiple input voltage welders are shipped from the fac-tory connected for the highest voltage listed on themachine's rating plate. Before installing the welder, besure the reconnect panel is connected for the propervoltage. Failure to follow these instructions can cause immedi-a...
Page 13 - OUTPUT TERMINAL CONNECTIONS
INSTALLATION A-7 A-7 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 2 1 + - FIGURE A.5 OUTPUT TERMINAL CONNECTIONS 1. NEGATIVE (-) WELDING CABLE CONNEC...
Page 14 - CONNECT WIRE FEEDERS; Accessories section of this manual for specif-
CONNECT WIRE FEEDERS The wire feeder control cable can connect to the CV-400 at the 14-pin amphenol on the front of the machine(with the appropriate adapter cable) or the terminalstrips behind the hinged control panel cover. A strainrelief box connector is provided for cable access to theterminal st...
Page 15 - Operation
Section B-1 Section B-1 IDEALARC CV-400 TABLE OF CONTENTS - OPERATION SECTION - Operation ............................................................................................................................... Section B Safety Precautions ........................................................
Page 16 - OPERATION; OPERATING INSTRUCTIONS
OPERATION B-2 B-2 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstruction...
Page 17 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES
GENERAL DESCRIPTION The IDEALARC CV-400 is an SCR controlled three-phase input, DC output power source for welding. Ituses a single range potentiometer control. Thewelder's unique combination of transformer, threephase hybrid rectifier, capacitor bank, output choke,and solid state control system del...
Page 18 - Amps
WELDING CAPABILITY The CV-400 has the following duty cycle ratings. If theduty cycle is exceeded, a thermal protector will shut offthe machine output until it cools to normal operatingtemperature. The amber thermal protection indicatorlight will turn on until the machine cools. *Based on a 10 minute...
Page 19 - CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS
1. POWER SOURCE PILOT LIGHT: This light indi- cates that the power source input contactor is ener-gized (closed). This also means that the main powertransformer and all auxiliary control transformers areenergized. 2. ON/OFF POWER TOGGLE SWITCH: Energizes or deengergizes the input contactor. The swit...
Page 20 - WELDING OPERATION; LOCAL CONTROL; Turn on the main AC input power to the machine.; REMOTE CONTROL; section for wire feeder installation infor-
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-6 B-6 IDEALARC CV-400 WELDING OPERATION LOCAL CONTROL The following procedures are for using the CV-400 inth...
Page 21 - PIN
OVERLOAD PROTECTION The power source is thermostatically protected withproximity thermostats against overload or insufficientcooling. One thermostat is located on the nose of thecenter bottom primary coil and a second thermostat isattached to the lead connecting the secondaries. Boththermostats are ...
Page 22 - NOTES
NOTES B-8 B-8 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 23 - Accessories
TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories .......................................................................................................
Page 24 - • CV-400 is used in conjunction with any LN-23P or; ACCESSORIES
OPTIONS/ACCESSORIES The following options/accessories are available for yourCV-400 from your local Lincoln Electric Distributor. FACTORY INSTALLED OPTIONS Diode Option - This internally installed option allowsuse of the cold start and cold electrode sensing fea-tures of the NA-3, NA-5, or NA-5R auto...
Page 25 - AUTOMATIC WIRE FEEDERS; NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400; GND; TERMINAL
ELECTRIC SHOCK can kill. • Only qualified personnel should per- form this maintenance. • Turn the input power OFF at the dis- connect switch or fuse box beforeworking on this equipment. • Do not touch electrically hot parts. • Insulate yourself from work and ground. • Always wear dry insulating glov...
Page 26 - NOTE: The connection diagram shown in; NA-5 WIRE FEEDER CONNECTION TO THE CV-400
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 withinsulating tape. b. An S-16586- X remote voltage sensing work lead is available for this purpose. c. Ke...
Page 28 - LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400; SEMIAUTOMATIC WIRE FEEDERS
ACCESSORIES C-6 C-6 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE C.4 LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 + - ELECTRODECABLE TOA...
Page 31 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 IDEALARC CV-400 TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Sectio...
Page 32 - MAINTENANCE
SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this maintenance. • Turn the input power OFF at the discon- nect switch or fuse box before workingon this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE To avoid receiving an ele...
Page 33 - Major Component Locations
MAINTENANCE D-3 D-3 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC 9 10 11 8 7 6 5 1 2 3 4 FIGURE D.1 Major Component Locations 1. BASE2. CASE FRONT3. ...
Page 35 - FIGURE E.1 – BLOCK LOGIC DIAGRAM
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 IDEALARC CV-400 Theory of Operation ............................................................................................................. Section E General Description ...............
Page 36 - THEORY OF OPERATION; FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INPUT LINE VOLTAGE, CONTACTORAND MAIN TRANSFORMER The desired three-phase input power is connected tothe CV-400 through ...
Page 37 - Output current and voltage is; See SCR Operation
THEORY OF OPERATION E-3 E-3 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OUTPUT CONTROL,RECTIFICATION AND FEEDBACK The three-phase AC output from the...
Page 38 - FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT; If the customer accidentally
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC THEORY OF OPERATION E-4 E-4 IDEALARC CV-400 FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT #240 #41 CONTROL BOARD...
Page 39 - SCR OPERATION; As long as current continues to flow from; FIGURE E.5 – SCR OPERATION
SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminaldevice used to control rather large currents to a load.An SCR acts very much like a switch. When a gate sig-nal is applied to the SCR, it is turned ON, and there iscurrent flow from anode to cathode. In the ON state theSCR acts li...
Page 42 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; Symptoms are grouped; PERFORM EXTERNAL TESTS.; The
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...
Page 43 - PC BOARD TROUBLESHOOTING PROCEDURES
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on eq...
Page 44 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Control
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 IDEALARC CV-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beg...
Page 45 - If the amber thermal protection; Main Transformer
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-5 F-5 IDEALARC CV-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beg...
Page 46 - Check the remote control leads; Rectifier Bridge Test.; The control board may be
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 IDEALARC CV-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beg...
Page 47 - Also check associated; Check the input power switch; Input Contactor
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-7 F-7 IDEALARC CV-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beg...
Page 48 - Remove any external leads that
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-8 F-8 IDEALARC CV-400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beg...
Page 49 - WELDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-9 F-9 IDEALARC CV-400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beg...
Page 50 - DESCRIPTION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 IDEALARC CV-400 CONTROL TRANSFORMER (T2) VOLTAGE TEST WARNING Service and repair ...
Page 51 - FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS; TEST PROCEDURE; Disconnect the main input supply power to
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 IDEALARC CV-400 FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS CONTROL TRANS...
Page 52 - FIGURE F.2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS; RIGHT SIDE VIEW; MACHINE FRONT
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-12 F-12 IDEALARC CV-400 FIGURE F.2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS CONTR...
Page 54 - INPUT CONTACTOR TEST; FIGURE F.3 – INPUT CONTACTOR CONNECTIONS; Electric Shock can kill.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-14 F-14 IDEALARC CV-400 INPUT CONTACTOR TEST (continued) FIGURE F.3 – INPUT CONTACTOR CON...
Page 55 - TEST FOR CONTACT CONTINUITY; Disconnect the main input supply power to the; FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS
TEST FOR CONTACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remove the two leads connected to the input con- tactor coil, #233 and X1/#232. See Figure F.4 forlocation. 3. Using the external 120VAC supply, apply 120VAC to the terminals of the input contactor coil. If the ...
Page 57 - FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-17 F-17 IDEALARC CV-400 TEST PROCEDURE 1. Set the ON/OFF power switch to OFF. 2. Disconne...
Page 58 - Test with an AC voltmeter for proper main; FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-18 F-18 IDEALARC CV-400 8. Read the meter. a. If proper voltage is present for all threep...
Page 59 - Test with an AC voltmeter for 21VAC for
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 IDEALARC CV-400 12. Test for 115VAC between leads #31 and #32 on the terminal str...
Page 60 - Plug P1 PHASE ANGLE WINDING VOLTAGES; Expected VAC; FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION; Plug P1
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-20 F-20 IDEALARC CV-400 Plug P1 PHASE ANGLE WINDING VOLTAGES From Lead # To Lead # Expect...
Page 61 - STATIC SCR/DIODE RECTIFIER BRIDGE TEST
STATIC SCR/DIODE RECTIFIER BRIDGE TEST 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 ormachine operator and will invalidate your factory warranty. For your safety and t...
Page 62 - FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-22 F-22 IDEALARC CV-400 STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.9 – C...
Page 63 - Remove any red insulating paint from the; FIGURE F.11 – HEAT SINK AND SCR TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-23 F-23 IDEALARC CV-400 STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) 8. Remove any ...
Page 64 - ACTIVE SCR TEST
ACTIVE SCR TEST 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 ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-trical sho...
Page 65 - FIGURE F.12 – CONTROL BOARD PLUG
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-25 F-25 IDEALARC CV-400 ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Disconnect the main...
Page 66 - FIGURE F.15 – HEAT SINK TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-26 F-26 IDEALARC CV-400 ACTIVE SCR TEST (continued) 8. Remove any red insulating paint fr...
Page 67 - Test the voltage level of the battery. Short; FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-27 F-27 IDEALARC CV-400 ACTIVE SCR TEST (continued) 9. Construct the circuit shown in Fig...
Page 68 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; MAXIMUM OUTPUT SETTING – NO LOAD; volts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 IDEALARC CV-400 This is the typical DC open circuitvoltage waveform generated fro...
Page 69 - TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-29 F-29 IDEALARC CV-400 This is the typical DC open circuitvoltage waveform generated fro...
Page 70 - TYPICAL SCR GATE VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-30 F-30 IDEALARC CV-400 This is the typical SCR gate pulsevoltage waveform. The machine w...
Page 71 - ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED; ONE OUTPUT SCR NOT FUNCTIONING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-31 F-31 IDEALARC CV-400 This is NOT the typical DC outputvoltage waveform. One output SCR...
Page 73 - FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL; CLEANING PROCEDURE; NOTE: Be sure to reconnect all leads correctly.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-33 F-33 IDEALARC CV-400 INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F.1...
Page 74 - FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT 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 ormachine operator and will invalidate your factory warranty. For your safety ...
Page 75 - FIGURE F.18 – FAN MOTOR MOUNTING DETAILS; PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-35 F-35 IDEALARC CV-400 FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F....
Page 77 - SCR/DIODE RECTIFIER ASSEMBLY
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-37 F-37 IDEALARC CV-400 SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT (continued) ...
Page 78 - SCR REMOVAL AND REPLACEMENT
SCR REMOVAL AND REPLACEMENT 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 ormachine operator and will invalidate your factory warranty. For your safety and to avoid ele...
Page 79 - FIGURE F.20 – SCR DETAILS; SPECIAL INSTRUCTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 IDEALARC CV-400 FIGURE F.20 – SCR DETAILS SCR REMOVAL AND REPLACEMENT (continued)...
Page 80 - FIGURE F.22 – CLAMP ASSEMBLY; Go to the procedure below that matches your
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-40 F-40 IDEALARC CV-400 FIGURE F.21 – 1/2” WIDE LEAF SPRING FIGURE F.22 – CLAMP ASSEMBLY ...
Page 81 - Do not turn the nuts. While holding the nuts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-41 F-41 IDEALARC CV-400 SCR REMOVAL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/...
Page 82 - FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-42 F-42 IDEALARC CV-400 SCR REMOVAL AND REPLACEMENT (continued) PROCEDURE FOR THE5/8 INCH...
Page 83 - AFTER REPLACING THE SCRs
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-43 F-43 IDEALARC CV-400 CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedure can...
Page 85 - Install the case top and sides.; DIODE STUD; MOUNTING OF STUD TYPE DIODES
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-45 F-45 IDEALARC CV-400 PROCEDURE 1. Remove the main input supply power to themachine. 2....
Page 86 - MAIN TRANSFORMER REMOVAL AND REPLACEMENT
MAIN TRANSFORMER REMOVAL AND REPLACEMENT 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 ormachine operator and will invalidate your factory warranty. For your safety and...
Page 87 - REMOVAL OF LIFT BAIL; MAIN TRANSFORMER REMOVAL & REPLACEMENT; FIGURE F.25 – LIFT BAIL REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-47 F-47 IDEALARC CV-400 REMOVAL OF LIFT BAIL 1. Remove the main input supply power to the...
Page 88 - FIGURE F.26 – CHOKE REMOVAL; Remove the top choke lead from the negative; NOTE: The coils may be “stuck” to the top iron; The leads from the coils that are to be
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-48 F-48 IDEALARC CV-400 FIGURE F.26 – CHOKE REMOVAL GLASTIC STIFFENERS CHOKELEADS TOP"...
Page 89 - FIGURE F.27 – EPOXY MIX APPLICATION AREAS; The following procedure describes a
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-49 F-49 IDEALARC CV-400 FIGURE F.27 – EPOXY MIX APPLICATION AREAS MAIN TRANSFORMER REMOVA...
Page 90 - FIGURE F.28 – COIL LEAD PLACEMENT
3. Install the bottom primary coils, one on each of the three legs of the bottom iron assembly. The coilsmust be in correct position (left, center, right).Place the coils so that the leads come out at theback of the machine. See Figure F.28 for properpositioning. 4. Place insulation (Lincoln Electri...
Page 91 - Mount the primary thermostat to the lead; FIGURE F.30 – PRIMARY THERMOSTAT LOCATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-51 F-51 IDEALARC CV-400 MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) 10. Mount ...
Page 92 - NOTE: The following procedure assumes you have; REASSEMBLE THE LIFT BAIL
REASSEMBLING THE MAINTRANSFORMER INTO THE MACHINE NOTE: The following procedure assumes you have completely reassembled the transformer coilsas described in the procedure above. Thelower iron has remained in place in themachine. See Figures F.25 and F.26. 1. Attach the bottom choke lead to the negat...
Page 93 - RETEST AFTER REPAIR; INPUT IDLE AMPS AND WATTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-53 F-53 IDEALARC CV-400 RETEST AFTER REPAIR Retest a machine: • If it is rejected under t...
Page 95 - ELECTRICAL DIAGRAMS
ELECTRICAL DIAGRAMS G-1 G-1 IDEALARC CV-400 Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Electrical Diagrams Section ...........................................................................................................Section G Wiring Diagram (Codes 1...
Page 100 - S N U B B E R
ELECTRICAL DIAGRAMS G-6 G-6 IDEALARC CV-400 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC I T E M P A R T N O . R E Q D D E S C R I P T I O N C 1 , C 2 , C 3 3 2 33 2...
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