Lincoln Electric IDEALARC SVM136-A manual

SVM136-A Nov ember 1997 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with saf ety in mind. How ev er , your o verall saf ety can be in- creased by proper installation . . . and thoughtful operation on your part. DO NO T INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANU AL AND THE SAFETY[...]

SAFETY i i IDEALARC CV -400 FOR ENGINE powered equipment. 1.a. T ur n the engine off bef ore troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b . Operate engines in open, well-v entilated areas or vent the engine e xhaust fumes outdoors. ______________[...]

SAFETY ii ii IDEALARC CV -400 ARC RA YS can burn. 4.a. Use a shield with the proper filter and cov er plates to protect your e yes from sparks and the ra ys of the arc when welding or obser ving open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b . Use suitable clothing made from durab le flame-resistant materi[...]

IDEALARC CV -400 FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse bo x before w or king on the equipment. 8.b . Install equipment in accordance with the U.S . National Electrical Code, all local codes and the manuf acturer’s recommendations. 8.c. Ground the equipment in accordance with the U.[...]

SAFETY iv iv IDEALARC CV -400 PRÉCA UTIONS DE SÛRETÉ P our 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 P our Soudage A L ’Arc 1. Protegez-vous contre la secousse électriq[...]

MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v IDEALARC CV -400 Page Safety ............................................................................................................................... ................ i-i-v Installation ..............................................................................................................[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION - Section A-1 Section A-1 IDEALARC CV -400 Installation ............................................................................................................................. Section A T echnical Specifications ........................................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 IDEALARC CV -400 TECHNICAL SPECIFICA TIONS - IDEALARC CV -400 INPUT - THREE PHASE ONL Y Standar d V oltage Input Current at Rated Output 230/460 77A/39A @ [...]

Read this entire installation section befor e you start installation. SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live par ts such as output ter minals or inter nal wiring. • Insulate yourself from the work and ground. • T urn power s witch off bef ore connecting or discon- necting cables or connections . • Alwa[...]

GROUND CONNECTION The frame of the welder m ust be grounded. An ear th grounding lead must be connected to the g rounding terminal, mar ked on the input bo x floor with the symbol (See Figure A.2 ). Ref er to T echnical Specifi- cations page f or proper ground wire size. INPUT SUPPL Y CONNECTIONS Be sure the v oltage, phase, and frequency of the in[...]

Hav e a qualified electrician connect the input power leads to the L1, L2, and L3 terminals of the input con- tactor . F ollow all national and local electrical codes. Use a three-phase line. Install the reconnect panel jumper links (see Figure A.3) f or the proper input volt- age. See the connection diagr am located on the inside cov er of the acc[...]

RECONNECT PR OCEDURE Multiple input voltage w elders are shipped from the f ac- tor y connected f or the highest voltage listed on the machine's rating plate . Before installing the welder , be sure the reconnect panel is connected f or the proper v oltage. F ailure to f ollow these instructions can cause immedi- ate f ailure of components in [...]

INST ALLA TION A-7 A-7 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 2 1 + - FIGURE A.5 OUTPUT TERMINAL CONNECTIONS 1. NEGA TIVE (-) WELDING CABLE CONNECTION 2. POSITIVE (+) WELDING CABLE CONNECTION T ABLE A[...]

CONNECT WIRE FEEDERS The wire f eeder 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 terminal strips behind the hinged control panel cover . A str ain relief bo x connector is provided f or cable access to the terminal str ips. The wire feeder grounding wire c[...]

Section B-1 Section B-1 IDEALARC CV -400 T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Saf ety Precautions ...................................................................................................[...]

OPERA TION B-2 B-2 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS EL[...]

GENERAL DESCRIPTION The IDEALARC CV -400 is an SCR controlled three- phase input, DC output power source f or welding. It uses a single range potentiometer control. The welder's unique combination of transf ormer , three phase h ybr id rectifier , capacitor bank, output choke , and solid state control system deliv er outstanding per- f or manc[...]

WELDING CAP ABILITY The CV -400 has the f ollowing duty cycle ratings. If the duty cycle is e xceeded, a thermal protector will shut off the machine output until it cools to nor mal operating temperature. The amber ther mal protection indicator light will tur n on until the machine cools. *Based on a 10 minute time period. For e xample, a 60% duty [...]

1. PO WER SOURCE PILO T LIGHT : This light indi- cates that the pow er source input contactor is ener- gized (closed). This also means that the main power transf or mer and all auxiliar y control transf or mers are energized. 2. ON/OFF PO WER T OGGLE SWITCH: Energizes or deengergizes the input contactor . The s witch tur ns the machine ON or OFF . [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-6 B-6 IDEALARC CV -400 WELDING OPERA TION LOCAL CONTROL The f ollowing procedures are f or using the CV -400 in the local control mode of operation. For remote contr[...]

OVERLOAD PROTECTION The pow er source is ther mostatically protected with pro ximity ther mostats against ov er load or insufficient cooling. One ther mostat is located on the nose of the center bottom primar y coil and a second thermostat is attached to the lead connecting the secondaries. Both ther mostats are connected in series with 2-4 circuit[...]

NO TES B-8 B-8 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - A CCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories ...................................................................................................................C-2 Options/Accessories .........[...]

OPTIONS/A CCESSORIES The f ollowing options/accessories are av ailable f or your CV -400 from your local Lincoln Electric Distributor . F ACTOR Y INST ALLED OPTIONS Diode Option - This inter nally installed option allows use of the cold star t and cold electrode sensing fea- tures of the NA-3, NA-5, or NA-5R automatic wire f eed- ers. See the topic[...]

ELECTRIC SHOCK can kill. • Only qualified personnel should per- f or m this maintenance. • T ur n the input power OFF at the dis- connect s witch or fuse box bef ore working on this equipment. • Do not touch electrically hot par ts. • Insulate yourself from w or k and ground. • Alwa ys wear dry insulating gloves . A uxiliar y power f or w[...]

5. Extend wire feeder control cab le lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using A WG #14 or larg- er insulated wire. T ape the bolted connection with insulating tape. b . An S-16586- X remote voltage sensing work lead is av ailable f or this pur pose. c. K eep the #21 lead electr ically separate fr[...]

A CCESSORIES C-5 C-5 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 5. Extend wire feeder control cab le lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using A WG #14 [...]

A CCESSORIES C-6 C-6 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE C.4 LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV -400 + - ELECTRODE CABLE TO AUTOMA TIC EQUIPMENT TO WORK NEGA TIVE POSITIVE TO LIN[...]

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 Figur e C.5. 4. Connect the wire feeder control cable gr ound lead to the frame terminal marked[...]

NO TES C-8 C-8 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 IDEALARC CV -400 T ABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Saf ety Precautions ............................[...]

SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perf orm this maintenance. • T ur n the input pow er OFF at the discon- nect s witch or fuse box bef ore working on this equipment. • Do not touch electrically hot par ts. R OUTINE AND PERIODIC MAINTENANCE T o av oid receiving an electr ic shock, k eep electrode ho[...]

MAINTENANCE D-3 D-3 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 9 10 11 8 7 6 5 1 2 3 4 FIGURE D.1 Major Component Locations 1. BASE 2. CASE FRONT 3. OUTPUT TERMINALS 4. CONTROL P ANEL 5. MAIN TRANSFORMER [...]

NO TES D-4 D-4 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 IDEALARC CV -400 Theory of Operation ............................................................................................................. Section E General Description .................................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INPUT LINE V OL T A GE, CONT A CT OR AND MAIN TRANSFORMER The desired three-phase input pow er is connected to the CV -400 through an input contactor , located in the input bo x [...]

THEOR Y OF OPERA TION E-3 E-3 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OUTPUT CONTR OL, RECTIFICA TION AND FEEDB A CK The three-phase A C output from the main transformer secondar y is rectified and con[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC THEOR Y OF OPERA TION E-4 E-4 IDEALARC CV -400 FIGURE E.4 – CV -400 TRIGGER AND THERMAL LIGHT CIRCUIT #240 #41 CONTROL BOARD #2 #4 #241 42A # #41 #2 #42 #240 CIRCUIT BREAKER SE[...]

SCR OPERA TION A silicon controlled rectifier (SCR) is a three-terminal de vice used to control rather large currents to a load. An SCR acts v er y much lik e a s witch. When a gate sig- nal is applied to the SCR, it is tur ned ON, and there is current flow from anode to cathode . In the ON state the SCR acts like a closed s witch. When the SCR is [...]

NO TES E-6 E-6 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 IDEALARC CV -400 T roub leshooting & Repair Section ................................................................................. Section F How to Use T roubleshooting Guide ............................................................[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HO W T O USE TR OUBLESHOO TING GUIDE Ser vice and repair should be perf or med by only Lincoln Electric F actor y T rained P ersonnel. Unauthorized repairs perf or med on this eq[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRIC SHOCK can kill. Hav e an electrician install and ser vice this equipment. T ur n the machine OFF bef ore working on equipment. Do not touch electrically hot par ts. Some[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-4 F-4 IDEALARC CV -400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CA UTION If f or any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-5 F-5 IDEALARC CV -400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-6 F-6 IDEALARC CV -400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CA UTION If f or any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-7 F-7 IDEALARC CV -400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-8 F-8 IDEALARC CV -400 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CA UTION If f or any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-9 F-9 IDEALARC CV -400 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CA UTION If f or any reason you[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-10 F-10 IDEALARC CV -400 CONTR OL TRANSFORMER (T2) V OL T A GE TEST W ARNING Ser vice and repair should be perf ormed by only Lincoln Electric f[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-11 F-11 IDEALARC CV -400 FIGURE F .1 – CONTROL TRANSFORMER AND LEAD LOCA TIONS CONTR OL TRANSFORMER (T2) V OL T A GE TEST (continued) TEST PRO[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-12 F-12 IDEALARC CV -400 FIGURE F .2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS CONTR OL TRANSFORMER (T2) V OL T A GE TEST (continued) 6[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-13 F-13 IDEALARC CV -400 W ARNING INPUT CONT A CT OR TEST Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained p[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-14 F-14 IDEALARC CV -400 INPUT CONT A CT OR TEST (continued) FIGURE F .3 – INPUT CONT ACTOR CONNECTIONS X1, #232 #233 TEST PROCEDURE 1. Discon[...]

TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remov e the two leads connected to the input con- tactor coil, #233 and X1/#232. See Figure F .4 f or location. 3. Using the external 120V A C supply , apply 120V AC to the ter minals of the input contactor coil. If the con- tactor does NO T activate , the inp[...]

MAIN TRANSFORMER (T1) V OL T A GE TEST Ser vice and repair should be perf or med by only Lincoln Electric f actor y trained personnel. Unauthorized repairs perf or med on this equipment ma y result in danger to the technician or machine operator and will in validate y our factory warranty . For y our saf ety and to av oid elec- trical shock, please[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-17 F-17 IDEALARC CV -400 TEST PROCEDURE 1. Set the ON/OFF power switch to OFF . 2. Disconnect main input supply power from the machine. 3. With [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-18 F-18 IDEALARC CV -400 8. Read the meter . a. If pr oper voltage is present for all thr ee phases, proper main input supply volt- age is being[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-19 F-19 IDEALARC CV -400 12. T est for 115V AC between leads #31 and #32 on the terminal strip. Also test for 42V AC between pin K (lead #42) an[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-20 F-20 IDEALARC CV -400 Plug P1 PHASE ANGLE WINDING VOL T AGES From Lead # T o Lead # Expected V AC 201 204 21 V AC 202 204 21 V AC 203 204 21 [...]

ST A TIC 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 r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe a[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-22 F-22 IDEALARC CV -400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F .9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCA TIONS FI[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-23 F-23 IDEALARC CV -400 ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) 8. Remove any red insulating paint from the heat sink test points.[...]

A CTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety notes and prec[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-25 F-25 IDEALARC CV -400 ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16?[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-26 F-26 IDEALARC CV -400 ACTIVE SCR TEST (continued) 8. Remove any red insulating paint from the heat sink test points. See Figure F .15. NOTE: [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-27 F-27 IDEALARC CV -400 ACTIVE SCR TEST (continued) 9. Construct the circuit shown in Figure F .16. One 6-volt lantern battery can be used., Se[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-28 F-28 IDEALARC CV -400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertic[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-29 F-29 IDEALARC CV -400 This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertic[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-30 F-30 IDEALARC CV -400 This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operati[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TR OUBLESHOO TING & REP AIR F-31 F-31 IDEALARC CV -400 This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “ripple” in the wav[...]

INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observ[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 IDEALARC CV -400 INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F .17 – INPUT CONT ACTOR CLEANING AND REMOV AL CLEANING [...]

F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please obse[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 IDEALARC CV -400 F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT (continued) FIGURE F .18 – F AN MOTOR MOUNTING DET AILS PROCEDURE 1. Remo[...]

SCR/DIODE RECTIFIER ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, pl[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 IDEALARC CV -400 SCR/DIODE RECTIFIER ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .19 – SCR/DIODE ASSEMBL Y DET AILS PROCEDUR[...]

SCR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe all safety no[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 IDEALARC CV -400 FIGURE F .20 – SCR DET AILS SCR REMOV AL AND REPLACEMENT (continued) SPECIAL INSTRUCTIONS NOTE: Before disassembling th[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 IDEALARC CV -400 FIGURE F .21 – 1/2” WIDE LEAF SPRING FIGURE F .22 – CLAMP ASSEMBL Y SCR REMOV AL AND REPLACEMENT (continued) 10. Go[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 IDEALARC CV -400 SCR REMOV AL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedur e can only be used [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-42 F-42 IDEALARC CV -400 SCR REMOV AL AND REPLACEMENT (continued) PROCEDURE FOR THE 5/8 INCH WIDE SPRING 1. Place a piece of sleeving around each [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 IDEALARC CV -400 CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedur e can only be used with 1/4-28 cap screws. Do not use cap sc[...]

MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEA T SINKS Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, plea[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-45 F-45 IDEALARC CV -400 PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver , remove the case top and [...]

MAIN TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may r esult in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid elec- trical shock, please observe [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 IDEALARC CV -400 REMOV AL OF LIFT BAIL 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver , remove the c[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 IDEALARC CV -400 FIGURE F .26 – CHOKE REMOV AL GLASTIC STIFFENERS CHOKE LEADS TOP "E" IRON THRU-BOL TS (4) BOTTOM "E"[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 IDEALARC CV -400 FIGURE F .27 – EPOXY MIX APPLICA TION AREAS MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) REASSEMBL Y OF TRAN[...]

3. Install the bottom primary coils, one on each of the three legs of the bottom ir on assembly . The coils must be in correct position (left, center , right). Place the coils so that the leads come out at the back of the machine. See Figure F .28 for proper positioning. 4. Place insulation (Lincoln Electric part number S20728) on top of each of th[...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 IDEALARC CV -400 MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) 10. Mount the primary thermostat to the lead end coil nose. See F[...]

REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE NOTE: The following procedur e assumes you have completely reassembled the transformer coils as described in the procedur e above. The lower iron has r emained in place in the machine. See Figures F .25 and F .26. 1. Attach the bottom choke lead to the negative out- put terminal. 2. Attach the top [...]

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 IDEALARC CV -400 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any r eason that requires you to r emove any [...]

NO TES F-54 F-54 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

ELECTRICAL DIA GRAMS G-1 G-1 IDEALARC CV -400 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Electrical Diagrams Section ........................................................................................................... Section G Wiring Diagram (Codes 10084, 10085, 10086) ...............................[...]

ELECTRICAL DIA GRAMS G-2 G-2 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 12-9-94F H2 H3 H4 ELECTRICAL SYMBOLS PER 1 2 4 3 4 PIN 8 PIN J3 J2 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD[...]

ELECTRICAL DIA GRAMS G-3 G-3 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC L9270 13 14 15 16 17 18 H2 H3 H4 ELECTRICAL SYMBOLS PER E1537 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P.C. BOARD) NOT[...]

ELECTRICAL DIA GRAMS G-4 G-4 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC IDENTIFICATION PART No. REQ’D. ITEM J1 J2 J3 QU3 R3 D3 D6 D9 D12 D15 D18 DZ3 R87 R19 R162 R165 R28 R171 R16 R168 R6 R9 R13 R31 SCR[...]

ELECTRICAL DIA GRAMS G-5 G-5 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC +15V 1W 6.2V DZ12 PILOT R177-R189=68.1K 1/4W OUTPUT CIRCUIT 15W 1.5K R150 R178 10W 160 R151 R179 243 R174 R177 D81 243 R173 R180 15W[...]

ELECTRICAL DIA GRAMS G-6 G-6 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ITEM PART NO. REQD DESCRIPTION C1,C2,C3 3 2 3 3 2 1 R1,R2,R3 C4,C5 TP1,TP2,TP3 TP4,TP5 TP6 T11577-68 T12733-10 T13640-12 T13640-16 T[...]

ELECTRICAL DIA GRAMS G-7 G-7 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED) LM124 (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION = = OP AMPS = DIODES = RESISTORS MF[...]

NO TES G-8 G-8 IDEALARC CV -400 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]