Lincoln Electric IDEALARC CV-400-I manual

IDEALARC C V -400-I OPERA TOR’S MANUAL IM501-A June, 2002 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 thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS[...]

FOR ENGINE powered 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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[...]

FOR ELECTRICALL Y 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 C[...]

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 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 ?[...]

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 keep it handy for quick reference. Pay par[...]

vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Select Suitable Location .......................................................[...]

A-1 CV-400-I A-1 INST ALLA TION TECHNICAL SPECIFICA TIONS – 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 36 32 34 29 Auxiliary Power 42 Volts AC, 10 Amps 115 Volts AC, 5 Amps (Except Code 10182) 220 Volt[...]

A-2 INST ALLA TION CV-400-I A-2 Read entire installation section before starting installation. SAFETY PRECAUTIONS SELECT SUIT ABLE LOCA TION Place the welder where clean cooling air can freely circulate in through the side louvers and out through the rear louvers. Dirt, dust or any foreign material that can be drawn into the welder should be kept a[...]

A-3 INST ALLA TION CV-400-I A-3 FIELD INST ALLED OPTIONS For installation of compatible field installed options (see the ACCESSORIES section of this manual and refer to the instructions included with those options. REQUIRED EQUIPMENT -CONTROL CABLE CONNECTIONS Follow the instructions below which are appropriate for the wire feeder that will be used[...]

A-4 INST ALLA TION CV-400-I A-4 P ARALLELING The CV-400-I is not designed to be paralleled with any other power source. CONNECTION OF AUXILIAR Y EQUIPMENT T O THE WIRE FEEDER RECEPT ACLE Occasionally, it may be necessary to make connection to the circuits present in the 14-pin wire feeder recep- tacle. These circuits, such as the auxiliary voltage,[...]

B-1 OPERA TION B-1 CV-400-I ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from 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[...]

B-2 OPERA TION B-2 When using a CV-400-I power source with wire feeders, there will be a small spark if the electrode contacts the work or ground within several seconds after releasing the trigger. When used with some wire feeders with the electrical trigger interlock in the ON position, the arc might restart if the electrode touches the work or gr[...]

B-3 OPERA TION 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 "E10" when this occurs. When the light turns o[...]

B-4 OPERA TION B-4 J. WIRE FEEDER VOLTMETER SWITCH - This switch selects the polarity of the wire feeder voltmeter, if so equipped. When weld- ing electrode positive (MIG, Outershield and some Innershield processes) set the switch to "+". - When welding electrode negative (most Innershield electrodes) set the switch to "-". - Th[...]

B-5 OPERA TION B-5 CV-400-I A., B., C. OUTPUT CONNECTORS -Each connector is a Magnum Twist-Mate™, receptacle. Insert a mating Twist-Mate™ plug, and twist clockwise to secure. For GMAW processes, and most FCAW processes, the positive output connection goes to the wire feeder. One of the negative output connections goes directly to the work. A. P[...]

B-6 OPERA TION B-6 CV-400-I A. 220 VAC RECEPTACLE Continental European type, nonpolarized, ground- ed receptacle (also known as a "Schuko" type) for connection of water coolers or other equipment. B. CIRCUIT BREAKER Protects the 220 volt auxiliary circuit from over- loads and shorts. If this breaker opens, the CV 400-I will work normally;[...]

B-7 OPERA TION B-7 ST ARTING THE MACHINE The power switch at the extreme right side of the con- trol panel energizes the CV-400-I. ADJUSTING THE OUTPUT VOL T AGE USING THE DIGIT AL METER The digital meters in the CV-400-I incorporate a voltage pre- set function. This allows the operator to set the desired welding voltage before striking an arc. The[...]

C-1 ACCESSORIES C-1 F ACT OR Y INST ALLED OPTIONS/ACCESSORIES There are no factory installed options/accessories on the CV-400-I. FIELD INST ALLED OPTIONS REMOTE VOL T AGE CONTROL (K857) The K857 consists of a control box with 25 feet (7.6 m) of four conductor cable. Installation of a K857 Remote Voltage Control in the CV-400-I requires a K864 Remo[...]

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 the welder with low pressure air at regular intervals to eliminate excessive[...]

E-1 TROUBLESHOOTING E-1 CV-400-I This Troubleshooting Guide is provided to help you locate and remedy possible prob- lems with machine setup or operation. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the m[...]

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 assistance before you proceed. CAUTION ERROR CODE TRO[...]

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 assistance before you proceed. CAUTION PROBLEMS PROBL[...]

E-4 TROUBLESHOOTING E-4 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 assistance before you proceed. CAUTION PROBLEMS PROBL[...]

E-5 TROUBLESHOOTING E-5 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 assistance before you proceed. CAUTION PROBLEMS PROBL[...]

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 Guidelines detailed throughout this manual PROBLEMS PROBL[...]

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 Boards Before replacing a PC board which is suspe[...]

E-8 TROUBLESHOOTING E-8 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 OUTPUT VOL T AGE The open circuit voltage of the machine should be 10 to 43 [...]

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 224A 224A 10A CIRCUIT BREAKER CB1 L1 CHOKE 2 42V 12V 12V - 204C [...]

F-2 DIAGRAMS F-2 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 224A 224A 10A CIRCUIT BREAKER CB1 L1 CHOKE 2 42V 12V 12V - 204C [...]

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. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE [...]

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 persons should install, use or service this machine. us[...]

F-5 DIAGRAMS F-5 CV-400-I CV POWER SOURCE TO A K867 / K775 / LN-7 N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. SPARE 82 81 42 41 31 32 2 4 21 GND 75 76 77 31 32 2 4 21 GND N.C. K291 OR K404 INPUT CABLE K775 OPTIONAL REMOTE CONTROL K867 UNIVERSAL ADAPTER PLUG 75 76 77 GREEN [...]

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 MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLI[...]

F-7 DIAGRAMS F-7 CV-400-I CV POWER SOURCE TO AN LN-25 / K444-1 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 MUST BE SIZED FOR CURRENT AND DUTY CYCLE[...]

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 (0) the power switch on the Welding AND 14-PIN CA[...]

F-9 DIAGRAMS F-9 CV-400-I K867 UNIVERSAL ADAPTER INST ALLA TION AND CONNECTION INSTRUCTIONS INSTALLATION INSTRUCTIONS THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE. WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS CONSULT [...]

F-10 DIAGRAMS F-10 CV-400-I TWIST -MA TE CABLE PLUG INST ALLA TION INSTRUCTIONS TURN THE POWER SWITCH OF THE WELDING POWER SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES OR WHEN CONNECTING OR DISCONNECTING PLUGS TO WELDING POWER SOURCE. 1. WELDING CABLE BOOT TRIM Slide the copper tube into the brass plug. Insert cable into copper tube. CO[...]

F-1 1 DIAGRAMS F-1 1 CV-400-I CONNECTION OF NON-LINCOLN WIRE FEEDERS[...]

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) .28 (7.0) 1.00 (25.4) 23.62 (600) 6.20 (157) 30.[...]

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W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

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