Lincoln Electric IDEALARC CV400 Service Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. IDEALARC CV-400
  6. Service manual

Lincoln Electric IDEALARC CV400 Service Manual

Hide thumbs Also See for IDEALARC CV400:
Table of Contents

Advertisement

Quick Links

Download this manual
IDEALARC
CV400, CV500-I
®
For use with machines having Code Numbers:
10084, 10085, 10086, 10087, 11087, 11088, 11089, 11354, 11355, 10088, 10089,
10090, 10091, 10092, 10277, 10278, 10279, 11356, SPLC58211
SERVICE MANUAL
SVM136-B
| Issue D ate 12-Apr
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IDEALARC CV400 and is the answer not in the manual?

Questions and answers

Related Manuals for Lincoln Electric IDEALARC CV400

Summary of Contents for Lincoln Electric IDEALARC CV400

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair IDEALARC CV400, CV500-I procedures for the code numbers listed. Some variances may exist when ® troubleshooting/repairing later code numbers. For use with machines having Code Numbers: 10084, 10085, 10086, 10087, 11087, 11088, 11089, 11354, 11355, 10088, 10089, 10090, 10091, 10092, 10277, 10278, 10279, 11356, SPLC58211 SERVICE MANUAL SVM136-B...

  • Page 2: California Proposition 65 Warnings

    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

    SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - 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 10: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - IDEALARC ® CV-400, CV-500-I INPUT - THREE PHASE ONLY Standard Voltage Input Current at Rated Output 230/460 (60Hz) 77A/39A @ 400A 36V 220/380/440 (50Hz) RATED OUTPUT Duty Cycle Welding Output Volts at Rated Amps 100% OUTPUT Current Voltage Maximum Open...

  • Page 11: Safety Precautions

    INSTALLATION Read this entire installation section before you The IDEALARC CV-400 weighs 357 pounds (162 kilo- ® grams). A permanent lift hook is located at the top of start installation. the machine, positioned at the center of gravity for sta- ble lifting.

  • Page 12: Ground Connection

    INSTALLATION FIGURE A.1 RATING PLATE LOCATION 1. RATING PLATE GROUND CONNECTION INPUT SUPPLY CONNECTIONS The frame of the welder must be grounded. An earth Be sure the voltage, phase, and frequency of the input grounding lead must be connected to the grounding power is the same as specified on the rating plate.

  • Page 13: Input Power Supply Connections

    INSTALLATION FIGURE A.2 INPUT WIRE AND FUSE SIZE REAR PANEL Fuse the input circuit with the super lag fuse recom- mended in the Technical Specifications at the begin- ning of this section or use delay type circuit breakers. Choose an input and grounding wire size according to local or national codes;...

  • Page 14: Reconnect Procedure

    TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN. 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES. 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS. PILOT TRANSF. THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. IDEALARC ® CV-400, CV-500I...

  • Page 15: Output Terminal Connections

    INSTALLATION FIGURE A.5 OUTPUT TERMINAL CONNECTIONS 1. NEGATIVE (-) WELDING CABLE CONNECTION 2. POSITIVE (+) WELDING CABLE CONNECTION TABLE A.1 - CABLE SIZES FOR COMBINED LENGTH OF ELECTRODE AND WORK CABLE MACHINE LOAD 400A 500A (100% DUTY (50% DUTY CABLE LENGTHS CYCLE) CYCLE) UP TO 50 ft...
  • Page 16 TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN. 4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC CODES. 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS. PILOT TRANSF. THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. IDEALARC ® CV-400, CV-500I...

  • Page 17: 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 18 NOTES A-10 A-10 IDEALARC ® CV-400, CV-500I...
  • Page 19 TABLE OF CONTENTS - 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 IDEALARC ®...

  • Page 20: Safety Instructions

    OPERATION OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself from the work and ground.

  • Page 21: Operation

    OPERATION GENERAL DESCRIPTION OPERATIONAL FEATURES AND CONTROLS The IDEALARC CV-400 is an SCR controlled three- ® phase input, DC output power source for welding. It The following operational controls are standard on the uses a single range potentiometer control. The IDEALARC ®...

  • Page 22: Welding Capability

    OPERATION WELDING CAPABILITY LIMITATIONS The CV-400 has the following duty cycle ratings. If the The IDEALARC CV-400 has no provisions for paral- ® duty cycle is exceeded, a thermal protector will shut off leling. It should not be used outdoors without rain shel- the machine output until it cools to normal operating tering.

  • Page 23: Controls And Settings

    OPERATION CONTROLS AND SETTINGS case front assembly. See Figure B.1 for their locations. All operator controls and settings are located on the FIGURE B.1 – CASE FRONT CONTROLS 1. POWER SOURCE PILOT LIGHT 6. DC AMMETER 2. ON/OFF POWER TOGGLE SWITCH 7.

  • Page 24: Welding Operation

    OPERATION WELDING OPERATION 3. Set the OUTPUT CONTROL switch to "Local." (Exception: when using an LN-9, LN-9 GMA, or NA- LOCAL CONTROL 5 wire feeder, set the switch to "Remote." Otherwise, the wire feeder may automatically shut The following procedures are for using the CV-400 in down.) the local control mode of operation.

  • Page 25: Overload Protection

    OPERATION OVERLOAD PROTECTION AUXILIARY POWER The power source is thermostatically protected with On machines above code 9400, the IDEALARC ® proximity thermostats against overload or insufficient 400 can provide nominally 115 volts AC and 42 volts cooling. One thermostat is located on the nose of the AC auxiliary power for operating wire feeding equip- center bottom primary coil and a second thermostat is ment and other accessories.
  • Page 26 NOTES IDEALARC ® CV-400, CV-500I...
  • Page 27 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories...........................Section C 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/C-5 Semiautomatic Wire Feeders LN-7, LN-8, LN-9 ..............C-6 IDEALARC ®...

  • Page 28: Factory-Installed Options

    This connects to terminals 75, The following options/accessories are available for 76, and 77 on the terminal strip and the case ground- your CV-400 from your local Lincoln Electric Distributor. ing screw marked with the symbol on the machine.

  • Page 29: Connection Of Lincoln Electric Automatic Or Semiautomatic Wire Feeders

    ACCESSORIES CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC WIRE FEEDERS WARNING NOTE: When using a CV-400 with wire feeders, there may be a small spark if the electrode contacts the work ELECTRIC SHOCK can kill. or ground within a few seconds after releasing the trig- ger.
  • Page 30 ACCESSORIES 5. Extend wire feeder control cable lead #21 so it can CONNECTING THE NA-5 TO THE be connected directly to the work piece. IDEALARC CV-400 ® a. Make a bolted connection using AWG #14 or larg- 1. Set the CV-400 POWER toggle switch to the OFF er insulated wire.
  • Page 31 ACCESSORIES 5. Extend wire feeder control cable lead #21 so it can NOTE: The connection diagram shown in Figure C.3 be connected directly to the work piece. shows the electrode connected for positive polarity. To change polarity: a. Make a bolted connection using AWG #14 or larg- er insulated wire.
  • Page 32 ACCESSORIES SEMIAUTOMATIC WIRE FEEDERS a. Make a bolted connection using AWG #14 or larg- er insulated wire. Tape the bolted connection with CONNECTING THE LN-7 TO THE insulating tape. IDEALARC ® CV-400 (TERMINAL STRIP) b. An S-16586- X remote voltage sensing work lead is available for this purpose.
  • Page 33 ACCESSORIES CONNECTING THE LN-8 OR LN-9 TO THE NOTE: Using the extended #21 lead eliminates the need to use the LN-9's remote work lead accessory, IDEALARC CV-400 ® which has a direct work lead jack. 1. Set the CV-400 POWER toggle switch to the OFF (0) 6.
  • Page 34 NOTES IDEALARC ® CV-400, CV-500I...
  • Page 35 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance .........................Section D Safety Precautions........................D-2 Routine and Periodic Maintenance.....................D-2 Major Component Locations.......................D-3 IDEALARC ® CV-400, CV-500I...

  • Page 36: Routine And Periodic Maintenance

    MAINTENANCE SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE WARNING WARNING ELECTRIC SHOCK can kill. To avoid receiving an electric shock, keep electrode holders and cable insulation in good condition. • Only qualified personnel should perform this maintenance. 1. Disconnect power supply lines to the machine before performing periodic maintenance.
  • Page 37 MAINTENANCE FIGURE D.1 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 IDEALARC ®...
  • Page 38 NOTES IDEALARC ® CV-400, CV-500I...
  • Page 39 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ......................Section E General Description .......................E-2 Input Line Voltage, Contactor and Main Transformer............E-3 Output Control, Rectification and Feedback................E-4 Protective Devices and Circuits.....................E-5 SCR Operation ........................E-6 FIGURE E.1 BLOCK LOGIC DIAGRAM OUTPUT CONTROL CONTROL TRANSFORMER NEGATIVE...

  • Page 40: Theory Of Operation

    THEORY OF OPERATION FIGURE E.2 - BLOCK LOGIC DIAGRAM OUTPUT CONTROL CONTROL TRANSFORMER NEGATIVE CONTROL BOARD OUTPUT TERMINAL POWER SWITCH MAIN TRANSFORMER OUTPUT CAPACITORS POSITIVE OUTPUT TERMINAL SHUNT INPUT SCR DIODE CONTACTOR HYBRID BRIDGE 115VAC REMOTE CONTROL CONTROL BOARD 42VAC 14 PIN AMPHENOL GENERAL DESCRIPTION The CV-400 is an SCR controlled three-phase DC...

  • Page 41: Input Line Voltage, Contactor And Main Transformer

    THEORY OF OPERATION FIGURE E.3 - INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER OUTPUT CONTROL CONTROL TRANSFORMER NEGATIVE CONTROL BOARD OUTPUT TERMINAL POWER SWITCH MAIN TRANSFORMER OUTPUT CAPACITORS POSITIVE OUTPUT TERMINAL SHUNT INPUT SCR DIODE CONTACTOR HYBRID BRIDGE 115VAC REMOTE CONTROL CONTROL BOARD...

  • Page 42: Output Control, Rectification And Feedback

    THEORY OF OPERATION FIGURE E.4 - OUTPUT CONTROL, RECTIFICATION AND FEEDBACK OUTPUT CONTROL CONTROL TRANSFORMER NEGATIVE CONTROL BOARD OUTPUT TERMINAL POWER SWITCH MAIN TRANSFORMER OUTPUT CAPACITORS POSITIVE OUTPUT TERMINAL SHUNT INPUT SCR DIODE CONTACTOR HYBRID BRIDGE 115VAC REMOTE CONTROL CONTROL BOARD 42VAC 14 PIN AMPHENOL...

  • Page 43: Protective Devices And Circuits

    THEORY OF OPERATION FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT THERMAL LIGHT #240 TERMINAL STRIP #241 CIRCUIT SECONDARY PRIMARY BREAKER THERMOSTAT THERMOSTAT #240 CONTROL BOARD PROTECTIVE DEVICES AND CIRCUITS Two thermostats protect the CV-400 from excessive The power source is also protected against overloads operating temperatures and overload conditions.

  • Page 44: Scr Operation

    THEORY OF OPERATION FIGURE E.5 – SCR OPERATION INPUT CATHODE OUTPUT ANODE GATE NOTE: AS THE GATE PULSE IS APPLIED LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED. GATE SCR OPERATION A silicon controlled rectifier (SCR) is a three-terminal An SCR is fired by a short burst current into the gate.
  • Page 45 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR 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-11 Control Transformer (T2) Voltage Test ................F-11 Input Contactor Test ......................F-15 Main Transformer (T1) Voltage Test ................F-19 Static SCR/Diode Rectifier Bridge Test .................F-25 Active SCR Test......................F-29...

  • Page 46: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by 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 47: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - 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- CAUTION er failure analysis.
  • Page 48 3. Perform the Main Transformer Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC ®...
  • Page 49 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC ®...
  • Page 50 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC ®...
  • Page 51 2. Perform the Input Contactor Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC ®...
  • Page 52 Check or replace. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC ®...
  • Page 53 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. IDEALARC ®...
  • Page 54 NOTES F-10 F-10 IDEALARC ® CV-400, CV-500I...

  • Page 55: Control Transformer (T2) Voltage Test

    CONTROL TRANSFORMER (T2) VOLTAGE TEST WARNING Service and repair should be performed only by 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 56 TROUBLESHOOTING AND REPAIR F-12 F-12 CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.1 – CONTROL TRANSFORMER AND LEAD CONNECTIONS PROCEDURE 5. Locate control transformer leads X1 (top) and 1. Disconnect the main input supply power to the machine. a. Lead X1 is connected to the input contactor 2.

  • Page 57: Right Side View

    TROUBLESHOOTING AND REPAIR F-13 F-13 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 METER PROBE RIGHT SIDE VIEW 6. Test for 115VAC between leads X1 and #231. 7.
  • Page 58 NOTES F-14 F-14 IDEALARC ® CV-400, CV-500I...

  • Page 59: Input Contactor Test

    INPUT CONTACTOR TEST WARNING Service and repair should be performed only by 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 60: Test Procedure

    TROUBLESHOOTING AND REPAIR F-16 F-16 INPUT CONTACTOR TEST (continued) FIGURE F.3 – INPUT CONTACTOR CONNECTIONS X1, #232 #233 TEST PROCEDURE 5. Apply the correct voltage to the machine and turn 1. Disconnect the main input supply power to the the power switch (S1) ON. machine.
  • Page 61 TROUBLESHOOTING AND REPAIR F-17 F-17 INPUT CONTACTOR TEST (continued) FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS APPLY EXTERNAL 120 VAC HERE X1, #232 (X1, #232 AND #233 LEAD TERMINALS) #233 TEST FOR CONTACT CONTINUITY 4. With the contactor activated, check the continu- 1.
  • Page 62 NOTES F-18 F-18 IDEALARC ® CV-400, CV-500I...

  • Page 63: Main Transformer (T1) Voltage Test

    MAIN TRANSFORMER (T1) VOLTAGE TEST WARNING Service and repair should be performed only by 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 64 TROUBLESHOOTING AND REPAIR F-20 F-20 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS PROCEDURE Set the ON/OFF power switch to OFF. 5. Connect main input supply power to the machine.
  • Page 65 TROUBLESHOOTING AND REPAIR F-21 F-21 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS 8. Read the meter. 11. Test with an AC voltmeter for approximately 42VAC across each of the three main sec- a. If proper voltage is present for all three ondary start leads located at the SCR/Diode phases, proper main input supply voltage Rectifier Bridge.
  • Page 66 TROUBLESHOOTING AND REPAIR F-22 F-22 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.7 – PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION 14-PIN AMPHENOL BLANK K=42 A=32 J=31 B=GND I=41 H=21 G=75 E=77 F=76 12. Test for 115VAC between leads #31 and #32 13.
  • Page 67 TROUBLESHOOTING AND REPAIR F-23 F-23 MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION G2629-[ CV-400/CV-500-I CONTROL #203 #204 #201 #202 Plug P3 Plug P1 Plug P1 PHASE ANGLE WINDING VOLTAGES From Lead # To Lead # Expected VAC 21 VAC 21 VAC...
  • Page 68 NOTES F-24 F-24 IDEALARC ® CV-400, CV-500I...

  • Page 69: Static Scr/Diode Rectifier Bridge Test

    STATIC SCR/DIODE RECTIFIER BRIDGE TEST WARNING Service and repair should be performed only by 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 70 TROUBLESHOOTING AND REPAIR F-26 F-26 STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.9 – CONTROL BOARD SNUBBER BOARD PLUG LOCATIONS G2629-[ CV-400/CV-500-I CONTROL #203 Plug P3 #204 #202 #201 M15370-[ ] SNUBBER Plug P1 FIGURE F.10 – CAPACITOR STRAP LEAD CONNECTIONS POSITIVE CAPACITOR STRAP LEAD...
  • Page 71 TROUBLESHOOTING AND REPAIR F-27 F-27 STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.11 – HEAT SINK AND SCR TEST POINTS ANODE REMOVE ANY INSULATING PAINT CATHODE (SCR) 8. Remove any red insulating paint from the heat a. Reverse the meter leads and measure the sink test points.
  • Page 72 NOTES F-28 F-28 IDEALARC ® CV-400, CV-500I...

  • Page 73: Active Scr Test

    ACTIVE SCR TEST WARNING Service and repair should be performed only by 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 74 TROUBLESHOOTING AND REPAIR F-30 F-30 ACTIVE SCR TEST (continued) FIGURE F.13 – SNUBBER BOARD FIGURE F.12 – CONTROL BOARD PLUG PLUG P5 LOCATION P1 AND P3 LOCATIONS G2629-[ CV-400/CV-500-I CONTROL Plug P5 #203 Plug P3 #204 #202 #201 M15370-[ ] SNUBBER Plug P1 FIGURE F.14 –...
  • Page 75 TROUBLESHOOTING AND REPAIR F-31 F-31 ACTIVE SCR TEST (continued) FIGURE F.15 – HEAT SINK TEST POINTS ANODE REMOVE ANY INSULATING PAINT CATHODE (SCR) 8. Remove any red insulating paint from the heat sink test points. See Figure F.15. NOTE: Do not disassemble the heat sinks. IDEALARC ®...
  • Page 76 TROUBLESHOOTING AND REPAIR F-32 F-32 ACTIVE SCR TEST (continued) FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS 9. Construct the circuit shown in Figure F.16. NOTE: Be sure the battery is functioning One 6-volt lantern battery can be used., Set properly.

  • Page 77: Normal Open Circuit Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-33 F-33 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING - NO LOAD 0 volts 2 ms 20 volts 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 78: Typical Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING AND REPAIR F-34 F-34 TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED 0 volts 5 ms 20 volts 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 79: Typical Scr Gate Voltage Waveform

    TROUBLESHOOTING AND REPAIR F-35 F-35 TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING - NO LOAD 0 volts 5 ms 2 volts This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operating properly.

  • Page 80: Abnormal Output Voltage Waveform - Machine Loaded

    TROUBLESHOOTING AND REPAIR F-36 F-36 ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED ONE OUTPUT SCR NOT FUNCTIONING 0 volts 5 ms 20 volts This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “ripple” in the waveform.

  • Page 81: Input Contactor (Cr1) Cleaning/Replacement

    INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT WARNING Service and repair should be performed only by 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 82 TROUBLESHOOTING AND REPAIR F-38 F-38 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 PROCEDURE CONTACTOR REPLACEMENT PROCEDURE Remove the main input supply power to the machine and remove the input access panel.

  • Page 83: Fan Motor And Blade Removal And Replacement

    FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by 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 84 TROUBLESHOOTING AND REPAIR F-40 F-40 FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.18 – FAN MOTOR MOUNTING DETAILS PROCEDURE Remove the main input supply power to the 5. Remove the four mounting nuts and associat- machine. ed flat and lock washers that hold the motor to the mounting bracket.

  • Page 85: Scr/Diode Rectifier Assembly Removal And Replacement

    REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by 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 86 TROUBLESHOOTING AND REPAIR F-42 F-42 SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.19 – SCR/DIODE ASSEMBLY DETAILS PROCEDURE assembly removal. Clear any necessary leads 1. Remove the main input supply power to the that might hinder removal. machine. 12. For reassembly, carefully place the SCR/ diode 2.

  • Page 87: Scr Removal And Replacement

    SCR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by 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 88: Special Instructions

    Failure to follow this procedure may result 8. Apply a thin (0.001” to 0.003”) layer of PEN- in subsequent damage of the SCR. Handle all ETROX A-13 (Lincoln Electric #E2529) or SCRs with care. PENETROX A, heat sink compound, to each heat sink’s SCR mounting surface.
  • Page 89 TROUBLESHOOTING AND REPAIR F-45 F-45 SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.22 – CLAMP ASSEMBLY 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 PROCEED- ING TO THE ASSEMBLY PROCEDURE.
  • Page 90 TROUBLESHOOTING AND REPAIR F-46 F-46 SCR REMOVAL AND REPLACEMENT (continued) CLAMPING PROCEDURE CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS FOR 1/4-20 CAP SCREWS NOTE: This procedure can only be used with 1/4- NOTE: This procedure can only be used with 1/4- 28 cap screws. 20 cap screws.
  • Page 91 TROUBLESHOOTING AND REPAIR F-47 F-47 SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING STEEL PRESSURE PAD HOUSING PROCEDURE FOR THE FIGURE F.24 – CLAMP ASSEMBLY 5/8 INCH WIDE SPRING 1. Place a piece of sleeving around each cap screw.
  • Page 92 TROUBLESHOOTING AND REPAIR F-48 F-48 SCR REMOVAL AND REPLACEMENT (continued) CLAMPING PROCEDURE CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS FOR 1/4-20 CAP SCREWS NOTE: This procedure can only be used with 1/4- NOTE: This procedure can only be used with 1/4- 28 cap screws. 20 cap screws.

  • Page 93: Mounting Of Stud Type Diodes To Aluminum Heat Sinks

    TO ALUMINUM HEAT SINKS WARNING Service and repair should be performed only by 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 94 TROUBLESHOOTING AND REPAIR F-50 F-50 MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS (continued) PROCEDURE DIODE STUD FOOT- INCH- 1. Remove the main input supply power to the SIZE POUNDS POUNDS machine. 3/4-16 25-27 300-324 2. With the 5/16” nut driver, remove the case top 3/8-24 10±.5 125+0/-5...

  • Page 95: Main Transformer Removal And Replacement

    MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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 96 TROUBLESHOOTING AND REPAIR F-52 F-52 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.25 – LIFT BAIL REMOVAL PROCEDURE 8. Using the 9/16” socket wrench, remove the four Remove the main input supply power to the bolts (left and right) mounting the lift bail to the machine.
  • Page 97 TROUBLESHOOTING AND REPAIR F-53 F-53 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.26 – CHOKE REMOVAL CHOKE LEADS "E" IRON GLASTIC THRU-BOLTS STIFFENERS BOTTOM "E" IRON PROCEDURE 1. Remove the three (two left and one right) glas- 5. Using a hoist, carefully lift the choke and top tic stiffeners connecting the negative rectifier iron assembly out and clear of the transformer plate and choke assembly to the main trans-...
  • Page 98 Adapt the procedure for the spe- cific coils you may be replacing. 1. Apply a coating of Lincoln Electric E2547 Epoxy Mix along both sides of the bottom iron (lamina- tion) assembly in the areas where the coil sides will be mounted.
  • Page 99 SECONDARY COIL LEADS PRIMARY COIL LEADS 2. Install the bottom primary coils, one on each of the 6. Place insulation (Lincoln Electric part number three legs of the bottom iron assembly. The coils must be in correct position (left, center, right). Place...

  • Page 100: Main Transformer

    10. If necessary, trim off excess secondary lead end coil nose. See Figure F.30. Place a stickout and TIG weld the leads together. small amount of Lincoln Electric E1603 See Figure F.31. Epoxy between the coil nose and the coil insulation and between the insulation and the thermostat.
  • Page 101 TROUBLESHOOTING AND REPAIR F-57 F-57 MAIN TRANSFORMER REMOVAL AND REPLACEMENT PROCEDURE (continued) REASSEMBLING THE MAIN REASSEMBLE THE LIFT BAIL TRANSFORMER INTO THE MACHINE 1. Carefully position the lift bail onto the machine base. Using the 9/16” socket wrench, attach the NOTE: The following procedure assumes you lift bail to the base of the machine with four have completely reassembled the trans-...

  • Page 102: Retest After Repair

    TROUBLESHOOTING AND REPAIR F-58 F-58 RETEST AFTER 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. • If you repair or replace any electrical components. INPUT IDLE AMPS AND WATTS Input Volts/Phase/Hertz Maximum Idle Amps...
  • Page 103 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (Codes 10084 thru 10278, 11354, 11356, 11835, 11837) (L9269) ......G-2 Wiring Diagram (Codes 11087 thru 11089, 11355, 11836) (L9270) ............G-3 Schematic - Machine (Codes 11354 thru 11837) (L15891) ..............G-4...
  • Page 104 ELEcTricaL DiaGrams WiriNG DiaGram - cODEs 10084 Thru 10278, 11354, 11356, 11835, 11837 (L9269) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. iDEaLarc ®...
  • Page 105 ELEcTricaL DiaGrams WiriNG DiaGram - cODEs 11087 Thru 11089, 11355, 11836 (L9270) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine. iDEaLarc ®...
  • Page 106 ELEcTricaL DiaGrams schEmaTic - cODEs 11354 Thru 11837 (L15891) ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: SCR com SCR phasing & bd. pwr THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
  • Page 107 ELEcTricaL DiaGrams schEmaTic - cONTrOL Pc BOarD (L9148) ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC. MANUFACTURING TOLERANCE PER E2056 SCALE: CONTROL:...
  • Page 108 ELEcTricaL DiaGrams schEmaTic - sNuBBEr Pc BOarD (s19687) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. iDEaLarc ® cV-400, cV-500i...

This manual is also suitable for:

Idealarc cv500-i1008410085100861008711087 ... Show all

Table of Contents