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Lincoln Electric IDEALARC SVM136-A Service Manual

Lincoln electric welder user manual
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IDEALARC
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be in-
creased by proper installation . . .
and thoughtful operation on
your part. DO NOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think
before you act and be careful.
World's Leader in Welding and Cutting Products
RETURN TO MAIN INDEX
For Machines with Code Numbers 10084 thru 10087
SERVICE MANUAL
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
CV-400
®
Premier Manufacturer of Industrial Motors
SVM136-A
November 1997

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Summary of Contents for Lincoln Electric IDEALARC SVM136-A

  • Page 1 IDEALARC For Machines with Code Numbers 10084 thru 10087 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be in- creased by proper installation . . . and thoughtful operation on your part.

  • Page 2: Safety

    Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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-vous contre la secousse électrique: a.

  • Page 6: Table Of Contents

    Welding Operation ...B-6 Overload Protection ...B-7 Auxiliary Power ...B-7 Accessories ...Section C Options/Accessories ...C-2 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders ...C-3 Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance...D-2 Major Component Locations...D-3 Theory of Operation ...Section E Troubleshooting and Repair ...Section F...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation...Section A Technical Specifications ...A-2 Safety Precautions ...A-3 Location and Ventilation ...A-3 Lifting ...A-3 Stacking ...A-3 Tilting ...A-3 Electrical Input Connections ...A-3 Ground Connection...A-4 Input Power Supply Connections...A-4 Input Wire and Fuse Size ...A-5 Reconnect Procedure ...A-6 Output Connections ...A-6 Connect Electrode and Work Leads to Output Terminals ...A-6...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - IDEALARC CV-400 INPUT - THREE PHASE ONLY Standard Voltage 230/460 Duty Cycle 100% Current Voltage Range Range 60 - 500 Amps 12 - 42 Volts RECOMMENDED INPUT WIRE AND FUSE SIZES Input Voltage/ Input Amps Frequency Rating on Volts/Hz Nameplate Height...

  • Page 9: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground. • Turn power switch off before connecting or discon- necting cables or connections.

  • Page 10: Ground Connection

    GROUND CONNECTION The frame of the welder must be grounded. An earth grounding lead must be connected to the grounding terminal, marked on the input box floor with the symbol (See Figure A.2 ). Refer to Technical Specifi- cations page for proper ground wire size.

  • Page 11: Input Power Supply Connections

    Technical Specifications . Using fuses or circuit breakers smaller than recommended may result in "nuisance" shut-offs from welder inrush currents, even if you are not weld- ing at high output currents. Also called "inverse time" or "thermal/magnetic" circuit breakers.

  • Page 12: Reconnect Procedure

    LINK LINES INPUT CONTACTOR PILOT TRANSF. THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. INSTALLATION OUTPUT CONNECTIONS CONNECT ELECTRODE AND WORK LEADS TO OUTPUT TERMINALS The output (welding) cables are connected to the out- put terminals marked "+" and "-" . These 1/2" terminals are located at the lower right and lower left corners of the front panel.
  • Page 13 1. NEGATIVE (-) WELDING CABLE CONNECTION 2. POSITIVE (+) WELDING CABLE CONNECTION TABLE A.1 - CABLE SIZES FOR COMBINED LENGTH CABLE LENGTHS UP TO 50 ft (15 m) 50 to 100 ft (15 to 30 m) 100 to 150 ft (30 to 46 m) 150 to 200 ft (46 to 61 m)

  • Page 14: Connect Wire Feeders

    INSTALLATION 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 terminal strips behind the hinged control panel cover. A strain relief box connector is provided for cable access to the terminal strips.

  • Page 15: Operation...............................................................................................................................section B Safety Precautions

    Section B-1 - OPERATION SECTION - Operation...Section B Safety Precautions ...B-2 General Description ...B-3 Recommended Processes...B-3 Operational Features and Controls ...B-3 Design Features ...B-3 Welding Capability ...B-4 Limitations...B-4 Controls and Settings...B-5 Welding Operation...B-6 Local Control...B-6 Remote Control...B-6 Overload Protection ...B-7 Auxiliary Power...B-7 TABLE OF CONTENTS IDEALARC CV-400...

  • Page 16: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not weld on containers that have held com- bustibles.

  • Page 17: General Description

    The IDEALARC CV-400 is an SCR controlled three- phase input, DC output power source for welding. It uses a single range potentiometer control. The welder's unique combination of transformer, three phase hybrid rectifier, capacitor bank, output choke, and solid state control system deliver outstanding per- formance.

  • Page 18: Welding Capability

    WELDING CAPABILITY The CV-400 has the following duty cycle ratings. If the duty cycle is exceeded, a thermal protector will shut off the machine output until it cools to normal operating temperature. The amber thermal protection indicator light will turn on until the machine cools. Duty Cycle* Amps 100%...

  • Page 19: Controls And Settings

    CONTROLS AND SETTINGS All operator controls and settings are located on the case front assembly. See Figure B.1 for their locations. FIGURE B.1 – CASE FRONT CONTROLS 1. POWER SOURCE PILOT LIGHT 2. ON/OFF POWER TOGGLE SWITCH 3. OUTPUT CONTROL POTENTIOMETER 4.

  • Page 20: Welding Operation

    WELDING OPERATION LOCAL CONTROL The following procedures are for using the CV-400 in the local control mode of operation. For remote control of the machine, see the Remote Control section. Before operating the machine, make sure you have all materials needed to complete the job. Be sure you are familiar with and have taken all possible safety precau- tions before starting work.

  • Page 21: Overload Protection

    OVERLOAD PROTECTION The power source is thermostatically protected with proximity thermostats against overload or insufficient cooling. One thermostat is located on the nose of the center bottom primary coil and a second thermostat is attached to the lead connecting the secondaries. Both thermostats are connected in series with 2-4 circuit.
  • Page 22 NOTES IDEALARC CV-400...
  • Page 23 Section C-1 Accessories...Section C Options/Accessories ...C-2 Options/Accessories...C-2 Factory Installed Options...C-2 Field Installed Options...C-2 Connection of Lincoln Electric Automatic or Semiautomatic Wire Feeders...C-3 Automatic Wire Feeders NA-3, NA-5...C-3 Semiautomatic Wire Feeders LN-7, LN-8, LN-9...C-6 TABLE OF CONTENTS - ACCESSORIES - IDEALARC CV-400...

  • Page 24: Options/Accessories

    OPTIONS/ACCESSORIES The following options/accessories are available for your CV-400 from your local Lincoln Electric Distributor. FACTORY INSTALLED OPTIONS Diode Option - This internally installed option allows use of the cold start and cold electrode sensing fea- tures of the NA-3, NA-5, or NA-5R automatic wire feed- ers.

  • Page 25: Connection Of Lincoln Electric Automatic Or Semiautomatic Wire Feeders

    CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS WARNING 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 before working on this equipment.
  • Page 26 5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using AWG #14 or larg- er insulated wire. Tape the bolted connection with insulating tape. b. An S-16586- X remote voltage sensing work lead is available for this purpose.
  • Page 27 5. Extend wire feeder control cable lead #21 so it can be connected directly to the work piece. a. Make a bolted connection using AWG #14 or larg- er insulated wire. Tape the bolted connection with insulating tape. b. An S-16586- X remote voltage sensing work lead is available for this purpose.

  • Page 28: Semiautomatic Wire Feeders

    SEMIAUTOMATIC WIRE FEEDERS CONNECTING THE LN-7 TO THE IDEALARC CV-400 (TERMINAL STRIP) 1. Set the CV-400 POWER toggle switch to the OFF (0) position. 2. Disconnect main AC input power to the CV-400. 3. Connect the wire feeder control cable leads to the CV-400 terminal strip as shown in Figure C.4.
  • Page 29 CONNECTING THE LN-8 OR LN-9 TO THE IDEALARC CV-400 1. Set the CV-400 POWER toggle switch to the OFF (0) position. 2. Disconnect main AC input power to the CV-400. 3. Connect the wire feeder control cable leads to the CV-400 terminal strip as shown in Figure C.5.
  • Page 30 NOTES IDEALARC CV-400...

  • Page 31: Routine And Periodic Maintenance

    Section D-1 Section D-1 TABLE OF CONTENTS -MAINTENANCE- Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance...D-2 Major Component Locations...D-3 IDEALARC CV-400...

  • Page 32: Routine And Periodic Maintenance

    2. In extremely dusty locations, dirt may clog the air channels, causing the welder to run hot. Periodically blow out dust and dirt from the inside of the machine with a low pressure air system. Be sure to clean the following components thoroughly.

  • Page 33: Major Component Locations

    1. BASE 2. CASE FRONT 3. OUTPUT TERMINALS 4. CONTROL PANEL 5. MAIN TRANSFORMER 6. CHOKE 7. SCR/DIODE BRIDGE 8. LEFT CASE SIDE 9. CASE TOP 10. RIGHT CASE SIDE 11. CASE BACK WITH FAN MOTOR ASSEMBLY MAINTENANCE FIGURE D.1 Major Component Locations IDEALARC CV-400...
  • Page 34 NOTES IDEALARC CV-400...
  • Page 35 Section E-1 -THEORY OF OPERATION SECTION- Theory of Operation ...Section E General Description ...E-1 Input Line Voltage, Contactor and Main Transformer ...E-2 Output Control, Rectification and Feedback ...E-3 Protective Devices and Circuits ...E-4 SCR Operation ...E-5 FIGURE E.1 – BLOCK LOGIC DIAGRAM CONTROL TRANSFORMER POWER...

  • Page 36: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER CONTROL TRANSFORMER POWER SWITCH MAIN TRANSFORMER INPUT CONTACTOR 115VAC REMOTE CONTROL CONTROL BOARD 42VAC 14 PIN AMPHENOL INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER The desired three-phase input power is connected to the CV-400 through an input contactor, located in the input box at the rear of the machine.

  • Page 37: Output Control, Rectification And Feedback

    THEORY OF OPERATION FIGURE E.3 – OUTPUT CONTROL, RECTIFICATION AND FEEDBACK CONTROL TRANSFORMER POWER SWITCH MAIN TRANSFORMER INPUT CONTACTOR 115VAC REMOTE CONTROL CONTROL BOARD 42VAC 14 PIN AMPHENOL OUTPUT CONTROL, RECTIFICATION AND FEEDBACK The three-phase AC output from the main transformer secondary is rectified and controlled through the SCR/diode bridge.

  • Page 38: Protective Devices And Circuits

    THEORY OF OPERATION FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT CIRCUIT BREAKER PROTECTIVE DEVICES AND CIRCUITS Two thermostats protect the CV-400 from excessive operating temperatures and overload conditions. Excess operating temperatures may be caused by insufficient cooling air or by operating the machine beyond the duty cycle and output rating.

  • Page 39: Scr Operation

    THEORY OF OPERATION INPUT CATHODE OUTPUT ANODE GATE GATE SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminal device 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 is current flow from anode to cathode.
  • Page 40 NOTES IDEALARC CV-400...
  • Page 41 Section F-1 TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section...Section F How to Use Troubleshooting Guide ...F-2 PC Board Troubleshooting Procedures...F-3 Troubleshooting Guide ...F-4 - F-9 Test Procedures ...F-10 Control Transformer (T2) Voltage Test ...F-10 Input Contactor Test ...F-13 Main Transformer (T1) Voltage Test...F-16 Static SCR/Diode Rectifier Bridge Test ...F-21 Active SCR Test...F-24 Oscilloscope Waveforms ...F-28...

  • Page 42: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 43: Pc Board Troubleshooting Procedures

    • If the PC Board uses protective shorting jumpers, don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- er failure analysis.

  • Page 44: Troubleshooting Guide

    - the pilot light is on. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 45 The input contactor (CR1) chatters. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216- 383-2531 or 1-800-833-9353.
  • Page 46 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
  • Page 47 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216- 383-2531 or 1-800-833-9353. detailed in the beginning of this manual.
  • Page 48 “hot.” If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. POSSIBLE AREAS OF...
  • Page 49 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353. detailed in the beginning of this manual.

  • Page 50: Control Transformer (T2) Voltage Test

    TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 51 F-11 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the top, case sides, and rear input panel. 3.
  • Page 52 F-12 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS MACHINE FRONT BACK OF CONTROL PANEL LEAD #231 CONNECTION RIGHT SIDE VIEW 6. Test for 115VAC between leads X1 and #231.

  • Page 53: Input Contactor Test

    F-13 TROUBLESHOOTING & REPAIR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 54 F-14 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.3 – INPUT CONTACTOR CONNECTIONS TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and the reconnect panel cover. 3.
  • Page 55 F-15 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS X1, #232 #233 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.

  • Page 56: Main Transformer (T1) Voltage Test

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 57 F-17 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS TEST PROCEDURE 1. Set the ON/OFF power switch to OFF. 2. Disconnect main input supply power from the machine.
  • Page 58 F-18 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS 8. Read the meter. a. If proper voltage is present for all three phases, proper main input supply volt- age is being supplied. b.
  • Page 59 F-19 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.7 – PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION BLANK 12. Test for 115VAC between leads #31 and #32 on the terminal strip. 42VAC between pin K (lead #42) and pin I (lead 41) in the 14-pin amphenol.
  • Page 60 F-20 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION Plug P3 From Lead # G2629-[ CV-400/CV-500-I CONTROL #202 Plug P1 PHASE ANGLE WINDING VOLTAGES To Lead # IDEALARC CV-400 F-20 #203 #204 #201 Plug P1...

  • Page 61: Static Scr/Diode Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec- trical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 62 F-22 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS G2629-[ CV-400/CV-500-I CONTROL #203 Plug P3 #202 TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides.
  • Page 63 F-23 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.11 – HEAT SINK AND SCR TEST POINTS ANODE REMOVE ANY INSULATING PAINT 8. Remove any red insulating paint from the heat sink test points. See Figure F.11. NOTE: Do not disassemble the heat sink. 9.

  • Page 64: Active Scr Test

    F-24 TROUBLESHOOTING & REPAIR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 65 F-25 TROUBLESHOOTING & REPAIR FIGURE F.12 – CONTROL BOARD PLUG P1 AND P3 LOCATIONS G2629-[ CV-400/CV-500-I CONTROL Plug P3 #202 TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides.
  • Page 66 F-26 TROUBLESHOOTING & REPAIR ANODE REMOVE ANY INSULATING PAINT 8. Remove any red insulating paint from the heat sink test points. See Figure F.15. NOTE: Do not disassemble the heat sinks. ACTIVE SCR TEST (continued) FIGURE F.15 – HEAT SINK TEST POINTS IDEALARC CV-400 F-26 CATHODE (SCR)
  • Page 67 F-27 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS 9. Construct the circuit shown in Figure F.16. One 6-volt lantern battery can be used., Set voltmeter scale low, at approximately 0-5 volts or 0-10 volts. 10.

  • Page 68: Normal Open Circuit Voltage Waveform

    F-28 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING – NO LOAD 20 volts 2 ms This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal divi- sion represents 2 milliseconds in time.

  • Page 69: Typical Output Voltage Waveform - Machine Loaded

    F-29 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED 20 volts 5 ms This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal divi- sion represents 5 milliseconds in time.

  • Page 70: Typical Scr Gate Voltage Waveform

    F-30 TROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING – NO LOAD 2 volts 5 ms This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operating properly. Note that each vertical division represents 2 volts and that each horizontal division represents 5 milliseconds in time.

  • Page 71: Abnormal Output Voltage Waveform - Machine Loaded

    F-31 TROUBLESHOOTING & REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING 20 volts 5 ms This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “ripple” in the waveform. One SCR gate is disconnected to simulate an open or non-functioning output SCR.

  • Page 72: Input Contactor (Cr1) Cleaning/Replacement

    TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 73 F-33 TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL 1. INPUT SUPPLY LINE 2. INPUT CONTACTOR CR1 3. RECONNECT PANEL CLEANING PROCEDURE 1. Remove the main input supply power to the machine and remove the input access panel. 2.

  • Page 74: Fan Motor And Blade Removal And Replacement

    TROUBLESHOOTING & REPAIR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 75 F-35 TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – FAN MOTOR MOUNTING DETAILS PROCEDURE 1. Remove the main input supply power to the machine. 2. Using the 5/16” nut driver, remove the case top and sides. 3.

  • Page 76: Scr/Diode Rectifier Assembly Removal And Replacement

    SCR/DIODE RECTIFIER ASSEMBLY 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 77 F-37 TROUBLESHOOTING & REPAIR SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – SCR/DIODE ASSEMBLY DETAILS PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3.
  • Page 78 TROUBLESHOOTING & REPAIR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 79 SCR mounting surfaces. 8. Apply a thin (0.001” to 0.003”) layer of PEN- ETROX A-13 (Lincoln Electric #E2529) or PENETROX A, heat sink compound, to each heat sink’s SCR mounting surface.
  • Page 80 F-40 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.21 – 1/2” WIDE LEAF SPRING 10. Go to the procedure below that matches your machine’s cap screws. NOTE WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PROCEEDING TO THE ASSEMBLY PROCEDURE. Two different designs of leaf springs and housings have been used to clamp the SCR to the rectifier.
  • Page 81 F-41 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedure can only be used with 1/4-28 cap screws. Do not use cap screws with any other type thread or new SCR will be damaged. Do not over tighten cap screws.
  • Page 82 F-42 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING STEEL PRESSURE PAD PROCEDURE FOR THE 5/8 INCH WIDE SPRING 1. Place a piece of sleeving around each cap screw.
  • Page 83 F-43 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedure can only be used with 1/4-28 cap screws. Do not use cap screws with any other type thread or new SCR will be damaged. Do not over tighten cap screws.

  • Page 84: Mounting Of Stud Type Diodes To Aluminum Heat Sinks

    MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...
  • Page 85 F-45 TROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS (continued) PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3. Loosen the appropriate diode nut and remove the diode that is to be replaced.

  • Page 86: Main Transformer Removal And Replacement

    TROUBLESHOOTING & REPAIR 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid elec-...

  • Page 87: Idealarc Cv

    F-47 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) REMOVAL OF LIFT BAIL 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3. Remove the two fiber baffles from the left and right sides of the lift bail adjacent to the main transformer.
  • Page 88 F-48 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) CHOKE LEADS REMOVAL OF CHOKE AND TOP IRON ASSEMBLY 1. Remove the three (two left and one right) glastic stiffeners connecting the negative rec- tifier plate and choke assembly to the main transformer thru-bolts.
  • Page 89 Adapt the procedure for the specific coils you may be replacing. 1. Apply a coating of Lincoln Electric E2547 Epoxy Mix along both sides of the bottom iron (lamination) assembly in the areas where the coil sides will be mounted.
  • Page 90 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 the three primary coils. The longer side of the insulation should be placed toward the front of the machine.
  • Page 91 FIGURE F.30 – PRIMARY THERMOSTAT LOCATION INSULATION 10. Mount the primary thermostat to the lead end coil nose. See Figure F.30. Place a small amount of Lincoln Electric E1603 Epoxy between the coil nose and the coil insulation and between the insulation and the thermostat.
  • Page 92 F-52 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE NOTE: The following procedure assumes you have completely reassembled the transformer coils as described in the procedure above. The lower iron has remained in place in the machine.

  • Page 93: Retest After Repair

    F-53 TROUBLESHOOTING & REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. Input Volts/Phase/Hertz 200/3/60 208/3/60...
  • Page 94 F-54 F-54 NOTES IDEALARC CV-400...

  • Page 95: Electrical Diagrams

    ELECTRICAL DIAGRAMS Electrical Diagrams Section ...Section G Wiring Diagram (Codes 10084, 10085, 10086) ...G-2 Wiring Diagram (Code 10087) ...G-3 Control PC Board (G2629-1) Layout...G-4 Control PC Board (G2629-1) Schematic ...G-5 Snubber PC Board (M15370-3) Layout ...G-6 Snubber PC Board (M15370-3) Schematic ...G-7 IDEALARC CV-400...
  • Page 96 ELECTRICAL DIAGRAMS Wiring Diagram (Codes 10084, 10085, 10086) DUAL & SINGLE VOLTAGE 2 3 0 / 4 0 0 V O L T A G E TO GROUND UNDER 346 VOLTS PER NATIONAL ( S H O W N C O N N E C T E D (SHOWN CONNECTED ELECTRICAL CODE F O R 2 3 0 V .
  • Page 97 ELECTRICAL DIAGRAMS Wiring Diagram (Code 10087) T1 MAIN TRANSFORMER AUXILIARY COILS PRIMARY BOTTOM X 1 S E C PRIMARY RECTIFIER ASSEMBLY GREEN GREEN SNUBBER SNUBBER BOARD BOARD VOLTMETER SWITCH .0047MFD 1400V OUTPUT CHOKE CIRCUIT BREAKER N.A. 212 210 211 213 212 210 211 213 GROUNDING STUD...
  • Page 98 Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
  • Page 99 ELECTRICAL DIAGRAMS Control PC Board (G2629-1) Schematic R151 R 1 7 7 R 1 7 8 R 1 7 9 R 1 8 0 R181 R 1 8 2 R 1 8 3 R 1 8 4 R 1 8 5 R 1 8 6 R 1 8 7 R 1 8 8...
  • Page 100 Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
  • Page 101 ELECTRICAL DIAGRAMS Snubber PC Board (M15370-3) Schematic IDEALARC CV-400...
  • Page 102 NOTES IDEALARC CV-400...

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