Manual Del Operador - CV400

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SVM136-A
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November 1997
View Safety Info
IDEALARC ® CV-400
For Machines with Code Numbers 10084 thru 10087
Safety Depends on You

View Safety Info
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.
View Safety Info
SERVICE MANUAL
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World’s Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
Sales and Service through subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
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i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you pur-
chase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
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.
FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and before welding.
devices in position and in good repair.Keep
hands, hair, clothing and tools away from V- 2.c. Exposure to EMF fields in welding may have other health
belts, gears, fans and all other moving parts effects which are now not known.
when starting, operating or repairing equip-
ment. 2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d.1. Route the electrode and work cables together - Secure
guards to perform required maintenance. Remove them with tape when possible.
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.2. Never coil the electrode lead around your body.
Always use the greatest care when working near moving
parts. 2.d.3. Do not place your body between the electrode and
___________________________________________________ work cables. If the electrode cable is on your right
1.f. Do not put your hands near the engine fan. Do not attempt to side, the work cable should also be on your right side.
override the governor or idler by pushing on the throttle con-
trol rods while the engine is running. 2.d.4. Connect the work cable to the workpiece as close as
___________________________________________________ possible to the area being welded.
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance 2.d.5. Do not work next to welding power source.
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
Mar ‘95
IDEALARC CV-400

ii ii
Return to Master TOC 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” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating

products.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95
IDEALARC CV-400

iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.

6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent 7.a. Use only compressed gas cylinders
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building

switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
IDEALARC CV-400

iv iv
Return to Master TOC SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique: 8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
a. Les circuits à l’électrode et à la piéce sont sous tension masse sur la charpente de la construction ou d’autres endroits
quand la machine à souder est en marche. Eviter toujours éloignés de la zone de travail, on augmente le risque de voir
tout contact entre les parties sous tension et la peau nue passer le courant de soudage par les chaines de levage,
ou les vétements mouillés. Porter des gants secs et sans câbles de grue, ou autres circuits. Cela peut provoquer des
trous pour isoler les mains. risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher met-
9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble de produit des fumeés toxiques.
soudage et la machine à souder en bon et sûr état defonc-
tionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à soud- ou autres produits irritants.
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines. 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
f. Si on utilise la machine à souder comme une source de le code “Code for safety in welding and cutting” CSA Standard
courant pour soudage semi-automatique, ces precautions W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger

PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais

enrouler le câble-électrode autour de n’importe quelle partie LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres

de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
IDEALARC CV-400

v v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
RETURN TO MAIN INDEX

Page
Safety ...............................................................................................................................................i-i-v
Installation.............................................................................................................................Section A
Technical Specifications ..............................................................................................................A-2
Safety Precautions ......................................................................................................................A-3
Location and Ventilation ..............................................................................................................A-3
Electrical Input Connections........................................................................................................A-3
Reconnect Procedure .................................................................................................................A-6
Output Connections ....................................................................................................................A-6
Operation...............................................................................................................................Section B
Safety Precautions ......................................................................................................................B-2
General Description ....................................................................................................................B-3
Controls and Settings..................................................................................................................B-5
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
How to Use Troubleshooting Guide ............................................................................................F-2
PC Board Troubleshooting Procedures ......................................................................................F-3
Troubleshooting Guide ................................................................................................................F-4
Test Procedures ........................................................................................................................F-10
Oscilloscope Waveforms...........................................................................................................F-28
Replacement Procedures..........................................................................................................F-32
Retest After Repair....................................................................................................................F-53
Parts Manual ...............................................................................................................................P-236
IDEALARC CV-400
DEC-97

Section A-1 Section A-1
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
Connect Wire Feeders ..........................................................................................................A-8
IDEALARC CV-400

A-2 A-2
INSTALLATION
Return to Section TOC
TECHNICAL SPECIFICATIONS - IDEALARC CV-400
INPUT - THREE PHASE ONLY

Standard Voltage Input Current at Rated Output
230/460 77A/39A @ 400A 36V
RATED OUTPUT
Duty Cycle Welding Output Volts at Rated Amps
100% 400 36*
60% 450 38
50% 500 40
OUTPUT
Current Voltage Maximum Open Auxiliary
Range Range Circuit Voltage Power
60 - 500 Amps 12 - 42 Volts 46 VDC 115 VAC, 10 Amps
42 VAC, 10 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES

Fuse Type 75° C Type 75° C
Input Voltage/ Input Amps (Super Lag) Copper Wire in Copper Ground
Frequency Rating on or Breaker Conduit AWG Wire in Conduit
Volts/Hz Nameplate Size (IEC) Sizes AWG (IEC) Sizes

230 77 125 3 (27 mm2) 6 (13 mm2)
460 39 60 8 (8.4 mm2) 10 (5.3 mm2)
PHYSICAL DIMENSIONS
Height2 Width Depth Weight
27.5 in. (699 mm) 22.2 in. (565 mm) 32.0 in. (813 mm) 357 lbs. (162 kg)
* No added capacity over NEMA rated 36V at 400 amps.

IDEALARC CV-400

A-3 A-3
INSTALLATION
Read this entire installation section before you The IDEALARC CV-400 weighs 357 pounds (162 kilo-
start installation. grams). A permanent lift hook is located at the top of
the machine, positioned at the center of gravity for sta-
ble lifting.
SAFETY PRECAUTIONS
WARNING STACKING
ELECTRIC SHOCK can kill. IDEALARC CV-400s may be stacked three high. The
bottom machine must be on a stable, hard, level sur-
• Do not touch electrically live face capable of supporting the weight of up to three
parts such as output terminals or machines (1071 pounds/486 kilograms). Be sure that
internal wiring. the two holes in the top front corners of the bottom
• Insulate yourself from the work machine line up with the holes in the base rails of the
and ground. machine above. Fasten the machines together with
5/16" bolts, lockwashers, and nuts through these holes.
• Turn power switch off before connecting or discon- The lift hook is positioned so that it fits without interfer-
necting cables or connections. ence under the base of the second machine.
• Always connect grounding terminal to a proper elec-
trical earth ground.
TILTING
Place the machine on a secure, level surface. Any sur-
Only qualified personnel should install, use, or ser- faces you place it on other than the ground must be
vice this equipment. firm, non-skid, and structurally sound.
LOCATION AND VENTILATION ELECTRICAL INPUT CONNECTIONS

Place the IDEALARC CV-400 where clean, cooling air Be sure the voltage, phase, and frequency of the input
can flow freely in through the front louvers and out power is as specified on the rating plate, located on the
through the rear louvers. Keep dust, dirt, and other for- case front control panel. See Figure A.1.
eign materials that can be drawn into the machine to a
minimum. Failure to observe these precautions can Input supply line entry is through a hole in the case rear
lead to excessive operating temperatures and nuisance top panel. A removable door covers the input connec-
shut-downs. tion box, which contains the input contactor (CR1) and
reconnect panel assembly for multiple voltage connec-
THE CV-400 carries an IP-21 environmental rating. tion. Input power is connected to the three line termi-
Locate indoors or shelter from falling water such as rain. nals on the input contactor. See Figure A.2.
LIFTING
WARNING
FALLING EQUIPMENT can cause injury.
• Do not lift this machine using the lift
hook if it is equipped with a heavy
accessory such as a trailer or a gas
cylinder.
• Lift only with equipment of adequate

lifting capacity.
• Be sure the machine is stable when lifting.
• Do not stack more than three high.
• Do not stack the CV-400 on top of any other machine.
IDEALARC CV-400

A-4 A-4
INSTALLATION
FIGURE A.1
RATING PLATE LOCATION
1
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.
terminal, marked on the input box floor with the symbol

(See Figure A.2). Refer to Technical Specifi- WARNING
cations page for proper ground wire size.
ELECTRIC SHOCK can kill.
• Have a qualified electrician
install and service this equip-
ment.
• Turn the input power off at the
fuse box before working on this
equipment.
• Do not touch electrically hot parts.
IDEALARC CV-400

A-5 A-5
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 type1 circuit breakers.
Choose an input and grounding wire size according to
local or national codes; also see the 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.
1
Also called "inverse time" or "thermal/magnetic" circuit breakers.
These circuit breakers trip faster as the magnetude of the fault cur-
rent increases.
FIGURE A.3
INPUT POWER SUPPLY CONNECTIONS
1. INPUT SUPPLY LINE ENTRY HOLE

2. INPUT CONTACTOR CR1
3. RECONNECT PANEL/JUMPER LINKS
4. GROUND TERMINAL
Have a qualified electrician connect the input power

leads to the L1, L2, and L3 terminals of the input con-
tactor. Follow all national and local electrical codes.
Use a three-phase line. Install the reconnect panel
jumper links (see Figure A.3) for the proper input volt-
age. See the connection diagram located on the inside 1. INPUT SUPPLY LINE
cover of the access panel cover. Also refer to 2. INPUT CONTACTOR
3. RECONNECT PANEL/JUMPER LINKS

Reconnect Procedure later in this section.
IDEALARC CV-400

A-6 A-6
INSTALLATION
RECONNECT PROCEDURE OUTPUT CONNECTIONS

Multiple input voltage welders are shipped from the fac- CONNECT ELECTRODE AND WORK
tory connected for the highest voltage listed on the LEADS TO OUTPUT TERMINALS
machine's rating plate. Before installing the welder, be
sure the reconnect panel is connected for the proper The output (welding) cables are connected to the out-
voltage. put terminals marked "+" and "-" . These 1/2" terminals
are located at the lower right and lower left corners of
Failure to follow these instructions can cause immedi- the front panel. See Figure A.5.
ate failure of components in the welder.
See Table A.1 for recommended cable sizes for com-
To reconnect a multiple voltage machine to a different bined lengths of electrode and work cables.
voltage, remove input power and change the position of
the jumper links on the reconnect panel. Follow the
input connection diagram, located on the inside access
panel cover, appropriate for your machine's input volt-
age. This same connection diagram is shown in Figure
A.4 below.
FIGURE A.4
INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZ
DUAL VOLTAGE MACHINE

Do not operate with covers
removed
Do not touch electrically live parts INPUT SUPPLY CONNECTION DIAGRAM
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.
Disconnect input power before Only qualified persons should install,
servicing use or service this equipment NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
LINK
{
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT
L3 W CR1
LEAST 600 VOLT INSULATION.
LINES
L2 V
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS
INPUT CONTACTOR
TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
L1 U
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC
GND H1 CODES.
H3 H2
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE
TRANSF. USE. SECURE THE REMAINING HEX NUTS IN PLACE.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK 1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
{
L3 W CR1 2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT
LINES LEAST 600 VOLT INSULATION.
L2 V
INPUT CONTACTOR 3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS
L1 U TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC

GND H1
H3 CODES.
H2
PILOT 5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
TRANSF.
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.

IDEALARC CV-400

A-7 A-7
INSTALLATION
FIGURE A.5
OUTPUT TERMINAL CONNECTIONS
1 2
- +
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 3/0 2/0
(15 m) 85 mm2 67 mm2
50 to 100 ft 3/0 2/0

(15 to 30 m) 85 mm2 67 mm2
100 to 150 ft 3/0 3/0

(30 to 46 m) 85 mm2 85 mm2
150 to 200 ft 3/0 3/0

(46 to 61 m) 85 mm2 85 mm2
200 to 250 ft 4/0 4/0

(67 to 76 m) 107 mm2 107 mm2
IDEALARC CV-400

A-8 A-8
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. The wire feeder grounding wire con-
nects to a chassis ground screw provided near the ter-
minal strips and marked with the ground symbol .
See the Accessories section of this manual for specif-
ic instructions for connecting the following automatic
and semiautomatic wire feeders to the CV-400:
Automatic Wire Feeders: NA-3, NA-5, NA-5R.
Semiautomatic Wire Feeders: LN-7, LN-7 GMA, LN-8,
LN-9, LN-9 GMA, LN-22, LN-23P, LN-25, LN-742.
IDEALARC CV-400

Section B-1 Section B-1
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 CV-400

B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
Read and understand this entire section of operating
instructions before operating the machine.
SAFETY INSTRUCTIONS
WARNING

• Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
• Insulate yourself from the 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.
WELDING SPARKS can cause

fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have held com-

bustibles.
ARC RAYS can burn.

• Wear eye, ear, and body protection.
Observe additional Safety Guidelines detailed in

the beginning of this manual.
IDEALARC CV-400

B-3 B-3
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 CV-400:
welder's unique combination of transformer, three
• Power Source Pilot Light
phase hybrid rectifier, capacitor bank, output choke,
and solid state control system deliver outstanding per- • ON/OFF Power Toggle Switch
formance.
• Output Control Potentiometer
• Output Control Switch (with Local or Remote posi-
RECOMMENDED PROCESSES tions)
The IDEALARC CV-400 is a constant voltage power • Auxiliary Power Connections for Wire Feeder and
source only. It is recommended for all open arc Other Equipment (115V and 42V)
processes including Innershield and all solid wire and • Thermal Protection Indicator Light
gas procedures within its capacity of 60 to 500 amps.
• Voltmeter "+" Electrode or "-" Electrode Switch
The CV-400 can be connected to wire feeding equip-

ment, including:
• Automatic wire feeders NA-3, NA-5, and NA-5R. DESIGN FEATURES
(Requires the CV-400 Diode Kit option to use the cold
• Input line voltage compensation keeps output con-
start and cold electrode sensing features of these
stant for fluctuations of ±10%.
feeders.)
• SCR control.
• Semiautomatic wire feeders LN-7, LN-7 GMA, LN8,
LN-9, LN-9 GMA, LN-22, LN23P, LN-25, and LN-742. • Hinged front control panel provides easy access to
printed circuit boards and other control circuitry.
• Fully enclosed fan motor with permanently lubricated,
sealed ball bearings needs no maintenance.
• Fully recessed control panel protects controls and
minimizes accidental contact.
• Recessed output terminals reduce chance of acci-
dental contact.
• Low profile case permits installation under a work-
bench.
• Removable rear access panel provides easy access
to input contactor and input lead connections.
• Removable case sides provide easy access for ser-
vice or inspection, even when machines are stacked.
• Double-dipped transformer, SCR bridge, and choke
resist corrosion.
IDEALARC CV-400

B-4 B-4
OPERATION
WELDING CAPABILITY LIMITATIONS

The CV-400 has the following duty cycle ratings. If the The IDEALARC CV-400 has no provisions for parallel-
duty cycle is exceeded, a thermal protector will shut off ing. It should not be used outdoors without rain shel-
the machine output until it cools to normal operating tering.
temperature. The amber thermal protection indicator
light will turn on until the machine cools.
Duty Cycle* Amps Volts

100% 400 36
60% 450 38
50% 500 40
*Based on a 10 minute time period. For example, a 60% duty cycle

means 6 minutes on and 4 minutes off.
IDEALARC CV-400

B-5 B-5
OPERATION
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
8 9 10 11
1
7 6 5 4 3
1. POWER SOURCE PILOT LIGHT 6. DC AMMETER

2. ON/OFF POWER TOGGLE SWITCH 7. AUXILIARY POWER CONNECTIONS FOR WIRE FEEDER AND
3. OUTPUT CONTROL POTENTIOMETER OTHER EQUIPMENT (115V AND 42V)
4. OUTPUT CONTROL SWITCH (WITH LOCAL OR 8. VOLTMETER "+" ELECTRODE OR "-" ELECTRODE SWITCH
REMOTE POSITIONS) 9. THERMAL PROTECTION INDICATOR LIGHT
5. DC VOLTMETER
1. POWER SOURCE PILOT LIGHT: This light indi- 7. AUXILIARY POWER AND REMOTE CONTROL
cates that the power source input contactor is ener- CONNECTIONS FOR WIRE FEEDER AND OTHER
gized (closed). This also means that the main power EQUIPMENT (115V AND 42V): The 14-pin amphe-
transformer and all auxiliary control transformers are nol receptacle provides either 115 or 42 VAC as well
energized. as remote control connections. Terminal strips with
screw connections are located behind the hinged
2. ON/OFF POWER TOGGLE SWITCH: Energizes or
control panel for hard wired control. A strain relief
deengergizes the input contactor. The switch turns
connector is provided for cable entry. The 42 VAC
the machine ON or OFF. Position "I" is ON; position
auxiliary is not available at the terminal strip.
"0" is OFF.
8. VOLTMETER "+" ELECTRODE OR "-" ELEC-
3. OUTPUT CONTROL POTENTIOMETER: Controls
TRODE SWITCH: Selects the electrode polarity for
output voltage.
the remote work sensing lead (#21) when using
4. OUTPUT CONTROL SWITCH (WITH LOCAL OR automatic or semiautomatic wire feeders. It must
REMOTE POSITIONS): Selects the mode of control. agree with the actual electrode polarity chosen and
In the "Local" position, control is by the machine con- with the wire feeder polarity switch on the feeder.
trol panel. In the "Remote" position, control is by
9. THERMAL PROTECTON INDICATOR LIGHT: This
either a wire feeder unit or through an optional
light indicates that either of the two protective ther-
remote control device.
mostats has opened. Welding output is disabled but
5. DC VOLTMETER (OPTIONAL): Displays actual out- input power is still applied.

put voltage.
10. 42 VAC AUXILIARY CIRCUIT BREAKER: This 10
6. DC AMMETER (OPTIONAL): Displays actual output amp breaker protects the 42 VAC auxiliary circuit.
current.
11. 115 VAC AUXILIARY CIRCUIT BREAKER: This 10
amp breaker protects the 115 VAC auxiliary circuit.
IDEALARC CV-400

B-6 B-6
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 down.)
The following procedures are for using the CV-400 in
the local control mode of operation. For remote control 4. Set the ON/OFF switch to the ON position (I). The
of the machine, see the Remote Control section. power source pilot light glows and the fan starts.
Before operating the machine, make sure you have all 5. Set the OUTPUT CONTROL Potentiometer to the
materials needed to complete the job. Be sure you are desired voltage.
familiar with and have taken all possible safety precau- 6. Make the weld.
tions before starting work. It is important that you follow
these operating steps each time you use the machine.
1. Turn on the main AC input power to the machine. REMOTE CONTROL
2. Set the VOLTMETER "+" or "-" switch to the appro- The toggle switch on the control panel labeled "Output
priate position. Control Remote" gives you the option of controlling the
- Set toggle to " Electrode Negative" position if the machine output from a remote location. In the
electrode is connected to the negative (-) output ter- "Remote" position a wire feeder with remote control
minal. capabilities or a remote control device such as a K775
must be connected to the CV-400. See the
- Set toggle to "Electrode Positive" position if the elec- Accessories section for wire feeder installation infor-
trode is connected to the positive (+) output terminal. mation.
IDEALARC CV-400

B-7 B-7
OPERATION
OVERLOAD PROTECTION AUXILIARY POWER

The power source is thermostatically protected with On machines above code 9400, the IDEALARC CV-
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. This power is available at
attached to the lead connecting the secondaries. Both the 14-pin amphenol on the control panel and/or at the
thermostats are connected in series with 2-4 circuit. If terminal strip behind the hinged control panel on the
the machine is overloaded, the primary thermostat will case front. On the amphenol, 115 volts AC is available
open, the output will be zero, the amber thermal pro- at pins A and J (Domestic and Export models only); 42
tection light will be on and the fan will continue to run. volts AC is available at pins I and K. On the terminal
The secondary thermostat will open either with an strip, 115 volts AC is available at terminals 31 and 32;
excessive overload or insufficient cooling. The output 42 volts AC is not available at the terminal strip. The
will be zero, the amber protection light will be on and two circuits, 115 volts AC and 42 volts AC, are isolated;
the fan will continue to run. When the thermostats and each is protected by a 10 amp circuit breaker.
reset, the protection light will be off.
The power source is also protected against overloads

FRONT VIEW OF 14-PIN CONNECTOR
on the SCR bridge assembly through the solid state
RECEPTACLE
fault protection circuit. This circuit senses an overload
on the power source and limits the output to approxi- K=42
mately 550 amps by phasing back the SCR’s. A=32 J=31
Protection is provided to protect the circuitry from acci-
dental grounds. If leads 75, 76, or 77 are accidentally B=GND I=41
“grounded” to the positive output lead, the output will be
L N
reduced to a low value, thus preventing any damage to
the machine. If the ground occurs between 75, 76, 77 C=2 H=21
and the negative output lead, one of the PC board elec-
tronic “self-restoring” fuses will blow, preventing any
D=4 G=75
machine damage. After the ground is cleared, the
fuses automatically reset within a few seconds.
E=77 F=76
M
PIN LEAD NO. FUNCTION

A 32 115 VAC
B GND Chassis Connection
C 2 Trigger Circuit
D 4 Trigger Circuit
E 77 Output Control
F 76 Output Control
G 75 Output Control
H 21 Work Connection
I 41 42 VAC
J 31 115 VAC
K 42 42 VAC
L --- ---
M --- ---
N --- ---
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
B-8

NOTES
IDEALARC CV-400
B-8
Section C-1 Section C-1
TABLE OF CONTENTS
- ACCESSORIES -
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
IDEALARC CV-400

C-2 C-2
ACCESSORIES
OPTIONS/ACCESSORIES The K775 consists of a control box with 28 ft (8.5m) of

four conductor cable. This connects to terminals 75,
The following options/accessories are available for your 76, and 77 on the terminal strip and the case ground-
CV-400 from your local Lincoln Electric Distributor. ing screw marked with the symbol on the machine.
These terminals are located behind the control panel
FACTORY INSTALLED OPTIONS on the front. These devices will give the same control
Diode Option - This internally installed option allows as the output control on the machine.
use of the cold start and cold electrode sensing fea- Remote Control Adapter Cable (K864) - A "V" cable
tures of the NA-3, NA-5, or NA-5R automatic wire feed- 12 inches (.30 m) long to connect a K857 Remote
ers. See the topic Connecting the NA-3 [NA-5] to the Control with a wire-feeder control cable (14-pin con-
CV-400. nector) and the machine (14-pin connector). If a remote
Ammeter and Voltmeter - Display output current and control is used alone, the wire-feeder connection is not
voltage when welding. used. See Figure C.1.
FIELD INSTALLED OPTIONS Capacitor Discharge Circuit (K828-1) - Mounts inside

the CV-400. Recommended when:
The following options/accessories are available from
your local Lincoln Distributor. • CV-400 is used in conjunction with any LN-23P or
older LN-8 or LN-9 semiautomatic wire-feeder.
Undercarriage (K817P) - Includes a platform and Eliminates possible arc flash re-start of weld when
polyolefin wheels for easily moving the welder. trigger interlock is used. Not required with current LN-
Undercarriage (K841) - Includes a platform, wheels, 8 (above Code 8700), or LN-9s with serial numbers
and brackets for supporting the welder and two gas above 115187 (manufactured after 12/83), or any LN-
cylinders. 9 having an L6043-1 Power PC Board.
Remote Output Control (K775 or K857 with K864 • CV-400 is used with an LN-22 equipped with an older
Adapter Plug) - The K857 has a 6-pin MS-style con- K279 Contactor-Voltage Control Option. Eliminates
nector. The K857 requires a K864 adapter cable which electrode overrun when gun trigger is released. Not
connects to the 14-pin connector on the CV-400. required when later K279 (above Code 8800) is used.
• A small spark is objectionable if electrode touches
work just after the trigger is released.
FIGURE C.1
REMOTE CONTROL ADAPTER CABLE (K864)
STRAIGHT PLUG (14 PIN) CABLE RECEPTACLE (6 SOCKET)

TO POWER SOURCE TO K857 REMOTE CONTROL
CABLE RECEPTACLE (14 SOCKET)

TO: L-7 WIRE FEEDER
IDEALARC CV-400

C-3 C-3
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-
• Only qualified personnel should per- ger. With some wire feeders, when the electrical inter-
form this maintenance. lock is in the ON position the arc can restart if the elec-
trode touches the work or ground during these few sec-
• Turn the input power OFF at the dis- onds. Refer to K828-1 capacitor discharge circuit ear-
connect switch or fuse box before lier in this section.
working on this equipment.
The following descriptions show how to connect the
• Do not touch electrically hot parts. wire feeders using the terminal strip.
• Insulate yourself from work and ground.
• Always wear dry insulating gloves.
AUTOMATIC WIRE FEEDERS

CONNECTING THE NA-3 TO THE
Auxiliary power for wire feeder operation is available at
both a 14-pin amphenol and at terminal strips with
IDEALARC CV-400
screw-type connections located behind the hinged con- 1. Set the CV-400 POWER toggle switch to the OFF (0)
trol panel on the front of the machine. The 14-pin position.
amphenol can provide both 115 VAC (pins A and J) and
42 VAC (pins I and K). The terminal strip provides only 2. Disconnect main AC input power to the CV-400.
115 VAC (terminals 31 and 32). The two circuits are iso- 3. Connect the wire feeder control cable leads to the
lated, and each is protected by a 10A circuit breaker. CV-400 terminal strip as shown in Figure C.2.
4. Connect the wire feeder control cable ground lead to
the frame terminal marked .
NOTE: The CV-400 must be properly grounded.
FIGURE C.2
NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400

NA-3 WIRE
FEEDER TERMINAL
CONTROL
CABLE STRIPS
TO
AUTOMATIC 21
CONTROL
BOX 4
GND 2
21 BLANK
4 31
2 32
31
32 75
76
75 77
76
77
- +
NEGATIVE POSITIVE
ELECTRODE
TO CABLE TO
WORK AUTOMATIC
EQUIPMENT
IDEALARC CV-400

C-4 C-4
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 (0)
er insulated wire. Tape the bolted connection with position.
insulating tape.
2. Disconnect main AC input power to the CV-400.
b. An S-16586- X remote voltage sensing work lead
is available for this purpose. 3. Connect the wire feeder control cable leads to the
CV-400 terminal strip as shown in Figure C.3.
c. Keep the #21 lead electrically separate from the
work cable circuit and connection. 4. Connect the wire feeder control cable ground lead to
the frame terminal marked .
d. Tape the #21 lead to the work cable for ease of
use. NOTE: The CV-400 must be properly grounded.
NOTE: The connection diagram shown in Figure C.2
shows the electrode connected for positive polarity. To
change polarity:
a. Set the CV-400 POWER toggle switch to the OFF

(0) position.
b. Move the electrode cable to the negative (-) output
terminal.
c. Move the work cable to the positive (+) output ter-
minal.
d. Set the VOLTMETER toggle switch to negative.
FIGURE C.3
NA-5 WIRE FEEDER CONNECTION TO THE CV-400
NA-5 WIRE
FEEDER
CONTROL
TERMINAL
CABLE STRIPS
TO
AUTOMATIC 21
CONTROL
BOX 4
GND 2
21 BLANK
4 31
2 32
31
32 75
76
75 77
76
77
- +
NEGATIVE POSITIVE
ELECTRODE
TO CABLE TO
WORK AUTOMATIC
EQUIPMENT
IDEALARC CV-400

C-5 C-5
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. Tape the bolted connection with a. Set the CV-400 POWER toggle switch to the OFF (0)
insulating tape. position.
b. An S-16586- X remote voltage sensing work lead b. Move the electrode cable to the negative (-) output
is available for this purpose. terminal.
c. Keep the #21 lead electrically separate from the c. Move the work cable to the positive (+) output termi-
work cable circuit and connection. nal.
d. Tape the #21 lead to the work cable for ease of d. Set the VOLTMETER toggle switch to negative (-).
use.
e. See NA-5 manual for changing welding polarity.
6. Connect NA-5 wire feeder control jumpers on
Voltage Control Board. See the NA-5 operator's
manual.
NOTE: For proper NA-5 operation, the electrode

cables must be secured under the clamp bar on the
left side of the NA-5 Control Box.
IDEALARC CV-400

C-6 C-6
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
1. Set the CV-400 POWER toggle switch to the OFF (0) is available for this purpose.
position. c. Keep the #21 lead electrically separate from the
2. Disconnect main AC input power to the CV-400. work cable circuit and connection.
3. Connect the wire feeder control cable leads to the d. Tape the #21 lead to the work cable for ease of
CV-400 terminal strip as shown in Figure C.4. use.
4. Connect the wire feeder control cable ground lead to 6. Set voltmeter toggle switch to match electrode polar-
the frame terminal marked . ity.
NOTE: The CV-400 must be properly grounded. NOTE: The connection diagram shown in Figure C-
4 shows the electrode connected for positive polari-
5. PERFORM THIS STEP ONLY IF THE LN-7 IS ty. To change polarity:
EQUIPPED WITH A METER KIT.

a. Set the CV-400 POWER toggle switch to the OFF
NOTE: If the work cable length is less than 25 feet (0) position
and the connections to the work piece are secure,
then wire feeder control cable lead #21 can be con- b. Move the electrode cable to the negative (-) output
nected directly to the CV-400 terminal strip. terminal.
Extend wire feeder control cable lead #21 so it can c. Move the work cable to the positive (+) output ter-
be connected directly to the work piece. minal.
d. Set the VOLTMETER toggle switch to negative (-).
FIGURE C.4
LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400
NA-7 WIRE
FEEDER TERMINAL
CONTROL
CABLE STRIPS
TO
LINE-7 21
INPUT
CABLE 4
PLUG GND 2
21 BLANK
4 31
2 32
31
32 75
76
75 77
76
77
- +
NEGATIVE POSITIVE
ELECTRODE
TO CABLE TO
WORK AUTOMATIC
EQUIPMENT
IDEALARC CV-400

C-7 C-7
ACCESSORIES
CONNECTING THE LN-8 OR LN-9 TO THE NOTE: Using the extended #21 lead eliminates the
IDEALARC CV-400 need to use the LN-9's remote work lead accesso-
ry, which has a direct work lead jack.
1. Set the CV-400 POWER toggle switch to the OFF (0)
position. 6. Connect the LN-9 wire feeder control jumpers on
the Voltage Control board. See LN-9 operator's
2. Disconnect main AC input power to the CV-400. manual.
3. Connect the wire feeder control cable leads to the NOTE: The connection diagram shown in Figure C.5
CV-400 terminal strip as shown in Figure C.5. shows the electrode connected for positive polarity.
4. Connect the wire feeder control cable ground lead To change polarity:
to the frame terminal marked . a. Set the CV-400 POWER toggle switch to the OFF
5. Extend wire feeder control cable lead #21 so it can (0) position.
be connected directly to the work piece. b. Move the electrode cable to the negative (-) out-
a. Make a bolted connection using AWG #14 or put terminal.
larger insulated wire. Tape the bolted connection c. Move the work cable to the positive (+) output
with insulating tape. terminal.

b. An S-16586- X remote voltage sensing work lead d. Set the VOLTMETER toggle switch on power
is available for this purpose. source to negative (-).
c. Keep the #21 lead electrically separate from the e. Set the voltmeter toggle switch on feeder (if
work cable circuit and connection. equipped) to match electrode polarity.
d. Tape the #21 lead to the work cable for ease of
use.
FIGURE C.5
LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400
LN-8 ORLN-9
WIRE FEEDER TERMINAL
CONTROL CABLE STRIPS
TO
INPUT 21
CABLE
4
GND 2
21 BLANK
4 31
2 32
31
32 75
76
75 77
76
77
- +
NEGATIVE POSITIVE
ELECTRODE
TO CABLE TO
WORK AUTOMATIC
EQUIPMENT
IDEALARC CV-400

C-8

NOTES
IDEALARC CV-400
C-8
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

D-2 D-2
MAINTENANCE
SAFETY PRECAUTIONS ROUTINE AND PERIODIC

WARNING MAINTENANCE
WARNING
To avoid receiving an electric shock, keep electrode
• Only qualified personnel should perform holders and cable insulation in good condition.
this maintenance.
1. Disconnect power supply lines to the machine before
• Turn the input power OFF at the discon- performing periodic maintenance.
nect switch or fuse box before working
on this equipment. 2. In extremely dusty locations, dirt may clog the air
channels, causing the welder to run hot. Periodically
• Do not touch electrically hot parts. 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. See Figure D.1
for their location.
• Main transformer
• Output studs
• Polarity switch
• Rectifier assembly
• Control box assembly
3. Dirt and dust may also accumulate on the remote
control terminal strips. Wipe or blow off the terminal
strips regularly, especially in damp locations.
4. Inspect the welder output terminals and control
cables for fraying, cuts, and bare spots.
5. The fan motor has sealed ball bearings and requires
no maintenance.
IDEALARC CV-400

D-3 D-3
MAINTENANCE
FIGURE D.1
Major Component Locations
1. BASE
2. CASE FRONT 9
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 8
7 10
11
6
1
2
4
3
IDEALARC CV-400

D-4

NOTES
IDEALARC CV-400
D-4
Section E-1 Section E-1
TABLE OF CONTENTS
-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
OUTPUT
CONTROL
CONTROL
TRANSFORMER
CONTROL BOARD NEGATIVE

OUTPUT
G S
F TERMINAL
E
A I E
POWER T G D
SWITCH MAIN E N B
A A
TRANSFORMER L C
S K
R F
E E
E
C D
O B
A
N C
N OUTPUT K
E CAPACITORS
C POSITIVE
T OUTPUT
TERMINAL
INPUT SHUNT
SCR / DIODE
CONTACTOR HYBRID BRIDGE
T 115VAC
REMOTE E S
TO R
CONTROL CONTROL T
M
BOARD I R
N I FAN
A P
L s 42VAC
14 PIN AMPHENOL
GENERAL DESCRIPTION
The CV-400 is an SCR controlled three-phase DC
power source. It is designed for all open arc constant
voltage (CV) processes within the capacity of the
machine. The output characteristics have been opti-

mized for CV processes without the use of a variable
arc control. Minimum to maximum output is obtained
with a single potentiometer control.
IDEALARC CV-400

E-2 E-2
THEORY OF OPERATION
FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER
OUTPUT
CONTROL
CONTROL
TRANSFORMER

OUTPUT
G S
F TERMINAL
E
A I E
POWER T G D
SWITCH MAIN E N B
A A
TRANSFORMER L C
S K
R F
E E
E
C D
O B
A
N C
N
K
OUTPUT
E CAPACITORS
C POSITIVE
T OUTPUT
TERMINAL
INPUT SHUNT
SCR / DIODE
T 115VAC
REMOTE E S
TO R
CONTROL CONTROL T
M
BOARD I R
N I FAN
A P
L s 42VAC
14 PIN AMPHENOL
INPUT LINE VOLTAGE, CONTACTOR

AND MAIN TRANSFORMER
The desired three-phase input power is connected to The finishes or "neutrals" of the main secondary coils
the CV-400 through an input contactor, located in the are connected together, and the three starts of the sec-
input box at the rear of the machine. Two phases of the ondary windings are connected to the rectifier bridge
input line are also connected to the control transformer, assembly. In addition, the main transformer has sepa-
which, through the power switch, supplies power to rate and isolated 115VAC and 42VAC auxiliary wind-
activate the input contactor. ings. The 115VAC is available at the terminal strip and
the 14 pin amphenol and is protected by a 10 amp cir-
A reconnect panel allows the user to configure the
cuit breaker. The 42VAC is available at the 14 pin
machine for the desired input voltage. This AC voltage
amphenol only and is also protected by a 10 amp cir-
is applied to the primary of the main transformer.
cuit breaker. The three 21VAC phase angle windings
The transformer changes the high voltage, low current are also housed in the main transformer assembly.
input power to a lower voltage, higher current output. These windings provide power and "timing" for the con-
trol board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
IDEALARC CV-400

E-3 E-3
THEORY OF OPERATION
FIGURE E.3 – OUTPUT CONTROL, RECTIFICATION AND FEEDBACK
OUTPUT
CONTROL
CONTROL
TRANSFORMER

OUTPUT
G S
F TERMINAL
E
A I E
POWER T G D
SWITCH MAIN E N B
A A
TRANSFORMER L C
S K
R F
E E
E
C D
O B
A
N C
N K
OUTPUT
E CAPACITORS
C POSITIVE
T OUTPUT
TERMINAL
INPUT SHUNT
SCR / DIODE
T 115VAC
REMOTE E S
TO R
CONTROL CONTROL T
M
BOARD I R
N I FAN
A P
L s 42VAC
14 PIN AMPHENOL
OUTPUT CONTROL,
RECTIFICATION AND FEEDBACK
The three-phase AC output from the main transformer A "dry closure" of leads #2 and #4, either at the termi-
secondary is rectified and controlled through the nal strip or the 14 pin amphenol, signals the control
SCR/diode bridge. Output current and voltage is board to apply gate firing signals to the SCR/diode
sensed at the shunt and output capacitors, respective- bridge, which creates a DC voltage at the output of
ly. This feedback information is processed in the con- the bridge assembly. This output is filtered by the
trol board. The control board compares the commands capacitors to reduce the ripple content of the wave-
of the output control (or remote control) with the feed- form. Thus, a smoother DC output is created. The
back information and sends the appropriate gate firing choke, which is in series with the negative output ter-
signals to the SCR/diode bridge. See SCR Operation minal, stores energy and provides current filtering.
in this section.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
IDEALARC CV-400

E-4 E-4
THEORY OF OPERATION
FIGURE E.4 – CV-400 TRIGGER AND THERMAL LIGHT CIRCUIT
THERMAL
LIGHT
#42 #240
TERMINAL
STRIP
# 42A #241 #2 #2
CIRCUIT SECONDARY PRIMARY
BREAKER THERMOSTAT THERMOSTAT
#4
#240
#41
#41
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. on the SCR bridge assembly through the solid state
Excess operating temperatures may be caused by fault protection circuit. This circuit senses an overload
insufficient cooling air or by operating the machine on the power source and limits the output to approxi-
beyond the duty cycle and output rating. The primary mately 550 amps by phasing back the SCRs.
thermostat is located on the nose of the center bottom
Protection is also provided to protect the circuitry from
primary coil. The secondary thermostat is attached to
accidental grounds. If the customer accidentally
the lead connecting the secondaries. Both thermostats
"grounds" 75, 76, or 77 to the positive output lead, the
are connected in series with the trigger circuits. If the
CV-400 output will be reduced to a very low value, thus
machine is over-heated, the thermostats will open and
preventing any damage to the machine. If the ground
output will be zero. The thermal protection light will
occurs between 75, 76, and 77 and the negative output
glow and the fan will continue to run. See Figure E.4,
lead, one of the PC board electronic "self-restoring"
CV-400 Trigger And Thermal Light Circuit. Under nor-
fuses will blow, preventing any machine damage. After
mal conditions the Thermal Light is "shorted out" by
the ground is cleared, the fuses automatically reset
the circuit breaker and thermostat circuit. If the ther-

within a few seconds.

mostats or the circuit breaker opens, more current will
flow through the Thermal Light circuit, and the light will
glow.
IDEALARC CV-400

E-5 E-5
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.
device used to control rather large currents to a load. This gate pulse must be more positive than the cathode
An SCR acts very much like a switch. When a gate sig- voltage. Since there is a standard PN junction between
nal is applied to the SCR, it is turned ON, and there is gate and cathode, the voltage between these terminals
current flow from anode to cathode. In the ON state the must be slightly greater than 0.6V. Once the SCR has
SCR acts like a closed switch. When the SCR is turned fired, it is not necessary to continue the flow of gate
OFF, there is no current flow from anode to cathode; current. As long as current continues to flow from
thus the device acts like an open switch. As the name anode to cathode the SCR will remain on. When the
suggests, the SCR is a rectifier, so it passes current anode to cathode current drops below a minimum
only during positive half cycles of the AC supply. The value called holding current, the SCR will shut off. This
positive half cycle is the portion of the sine wave in normally occurs as the AC supply voltage passes
which the anode of the SCR is more positive than the through zero into the negative portion of the sine wave.
cathode. If the SCR is turned on early in the positive half cycle,
the conduction time is longer, resulting in greater SCR
When an AC supply voltage is applied to the SCR, the
output. If the gate firing occurs later in the cycle, the
device spends a certain portion of the AC cycle time in
conduction time is less, resulting in lower SCR output.
the ON state and the remainder of the time in the OFF
state. The amount of time spent in the ON state is con-
trolled by the gate.
IDEALARC CV-400

E-6

NOTES
IDEALARC CV-400
E-6
Section F-1 Section F-1
TABLE OF CONTENTS
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
Normal Open Circuit Voltage Waveform ........................................................................F-28

Typical Output Voltage Waveform - Machine Loaded....................................................F-29
Typical SCR Gate Voltage Waveform ............................................................................F-30
Abnormal Output Voltage Waveform - Machine Loaded ...............................................F-31
Replacement Procedures ....................................................................................................F-32
Input Contactor (CR1) Cleaning/Replacement..............................................................F-32
Fan Motor and Blade Removal and Replacement ........................................................F-34
SCR/Diode Rectifier Assembly Removal and Replacement .........................................F-36
Mounting of Stud Type Diodes to Aluminum Heat Sinks...............................................F-44
Main Transformer Removal and Replacement ..............................................................F-46
Retest After Repair ..............................................................................................................F-53
IDEALARC CV-400

F-2 F-2
TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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.
This Troubleshooting Guide is provided to help Step 3. PERFORM COMPONENT TESTS. The
you locate and repair possible machine malfunc- last column, labeled “Recommended Course of
tions. Simply follow the three-step procedure list- Action” lists the most likely components that may
ed below. have failed in your machine. It also specifies the

appropriate test procedure to verify that the sub-
ject component is either good or bad. If there are
Step 1. LOCATE PROBLEM (SYMPTOM). Look a number of possible components, check the
under the column labeled “PROBLEM” (SYMP- components in the order listed to eliminate one
TOMS). This column describes possible symp- possibility at a time until you locate the cause of
toms that the machine may exhibit. Find the list- your problem.
ing that best describes the symptom that the
machine is exhibiting. Symptoms are grouped
into two main categories: Output Problems and All of the referenced test procedures referred to in
Welding Problems. the Troubleshooting Guide are described in detail
at the end of this section. Refer to the
Troubleshooting and Repair Table of Contents to
Step 2. PERFORM EXTERNAL TESTS. The locate each specific Test Procedure. All of the
second column, labeled “POSSIBLE AREAS OF referred to test points, components, terminal
MISADJUSTMENT(S)”, lists the obvious external strips, etc., can be found on the referenced elec-
possibilities that may contribute to the machine trical wiring diagrams and schematics. Refer to
symptom. Perform these tests/checks in the order the Electrical Diagrams Section Table of Contents
listed. In general, these tests can be conducted to locate the appropriate diagram.
without removing the case cover.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the test/repairs
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before
you proceed. Call 216-383-2531 or 1-800-833-9353.
IDEALARC CV-400

F-3 F-3
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
• Remove the PC Board from the static-shielding bag
ELECTRIC SHOCK can kill. and place it directly into the equipment. Don’t set the
PC Board on or near paper, plastic or cloth which
Have an electrician install and service could have a static charge. If the PC Board can’t be
this equipment. Turn the machine OFF installed immediately, put it back in the static-shielding
before working on equipment. Do not bag.
touch electrically hot parts.
• If the PC Board uses protective shorting jumpers,
don’t remove them until installation is complete.
Sometimes machine failures appear to be due to PC • If you return a PC Board to The Lincoln Electric
board failures. These problems can sometimes be Company for credit, it must be in the static-shielding
traced to poor electrical connections. To avoid prob- bag. This will prevent further damage and allow prop-
lems when troubleshooting and replacing PC boards,
er failure analysis.
please use the following procedure:
4. Test the machine to determine if the failure symp-
tom has been corrected by the replacement PC
1. Determine to the best of your technical ability that board.
the PC board is the most likely component causing NOTE: Allow the machine to heat up so that all electri-
the failure symptom. cal components can reach their operating temperature.
2. Check for loose connections at the PC board to 5. Remove the replacement PC board and substitute
assure that the PC board is properly connected. it with the original PC board to recreate the original
3. If the problem persists, replace the suspect PC problem.
board using standard practices to avoid static elec- a. If the original problem does not reappear
trical damage and electrical shock. Read the warn- by substituting the original board, then the
ing inside the static resistant bag and perform the PC board was not the problem. Continue
following procedures: to look for bad connections in the control
PC Board can be damaged by wiring harness, junction blocks, and termi-
static electricity. nal strips.
• Remove your body’s static charge b. If the original problem is recreated by the
before opening the static-shielding substitution of the original board, then the
bag. Wear an anti-static wrist PC board was the problem. Reinstall the
strap. For safety, use a 1 Meg replacement PC board and test the
ATTENTION
Static-Sensitive ohm resistive cord connected to a machine.
Devices grounded part of the equipment 6. Always indicate that this procedure was followed
Handle only at frame. when warranty reports are to be submitted.
Static-Safe
Workstations • If you don’t have a wrist strap, NOTE: Following this procedure and writing on the
touch an unpainted, grounded, warranty report, “INSTALLED AND SWITCHED PC
part of the equipment frame. BOARDS TO VERIFY PROBLEM,” will help avoid
Reusable Keep touching the frame to pre- denial of legitimate PC board warranty claims.
Container vent static build-up. Be sure not to
Do Not Destroy touch any electrically live parts at
the same time.
• Tools which come in contact with the PC Board must
be either conductive, anti-static or static-dissipative.
IDEALARC CV-400

F-4 F-4
Observe Safety Guidelines TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local authorized 1. Contact the Lincoln Electric
is evident when the sheet metal Lincoln Electric Field Service Service Department, (216) 383-
cover(s) are removed. Facility for technical assistance. 2531 or 1-800-833-9353 (WELD).
Machine is dead - no output - no 1. Make sure the input power 1. Check the input power switch
fan - no pilot light. switch is ON. (S1) for proper operation. See
the Wiring Diagram.
2. Check the three-phase input

voltage at the machine. Input 2. Check the leads associated with
voltage must match the rating the power switch (S1) and the
plate and the reconnect panel. control transformer (T2) for
loose or faulty connections. See
3. Check for blown or missing
the Wiring Diagram.
fuses in the input lines.
3. Perform the Control
Transformer Test.
1. Check the three-phase input

The machine is dead - no output - voltage at the machine. Input 1. Perform the Input Contactor
no fan - the pilot light is on. voltage must match the rating Test.
plate and the reconnect panel.
2. Check the associated leads for
2. Check for blown or missing loose or faulty connections
fuses in the input lines. between the input contactor
(CR1), the reconnect panel and
the main transformer. See the

Wiring Diagram.
3. Perform the Main Transformer
Test.
CAUTION
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.
IDEALARC CV-400

F-5 F-5
TROUBLESHOOTING GUIDE Observe Safety Guidelines

OUTPUT PROBLEMS
The input contactor operates - the 1. If the amber thermal protection 1. Perform the Main Transformer
fan runs - the pilot light is on - but light is on, the primary or sec- Test.
the machine has no welding output. ondary thermostat is open.
Allow machine to cool. 2. Perform the SCR/Diode Recti-
fier Bridge Test.
2. Make certain the output trigger
circuit (#2 and #4) is being acti-
3. The control board may be faulty.
vated by a “closure.”
Replace.
3. Check the 10 amp circuit break-
er in the 42VAC circuit. Reset if

necessary.
4. If remote control is not being
used, make certain the Output
Control switch (S2) is in the
“Machine or Local” position.
5. Check for loose or faulty welding
cable connections.
The input contactor (CR1) chatters. 1. Make certain the three-phase 1. Perform the Input Contactor
input voltage matches the Test.
machine rating plate and the
reconnect panel.
CAUTION
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-
383-2531 or 1-800-833-9353.
IDEALARC CV-400

F-6 F-6

OUTPUT PROBLEMS
The machine has high welding out- 1. If remote control is being used, 1. Check the Output Control switch
put and no control. set the Output Control Switch (S2) and associated wiring. See
(S2) to the “Machine or Local” the Wiring Diagram.
position and control the weld
2. Check feedback leads #220,
output with the machine Output
#204, #205 and #206 for loose
Control (R4). If the problem is
or faulty connections.
solved, check the remote con-
trol unit or wire feeder and asso- 3. Perform the SCR/Diode
ciated control cable. Rectifier Bridge Test.

2. Check the remote control leads 4. The control board may be

for “grounds” to the negative faulty. Replace.
welding output. If leads #75,
#76 or #77 are “grounded” to the
negative welding output, the
machine output may go very
high without control.
The machine has minimum (or very 1. If remote control is being used, 1. Check the Output Control (R4)
low) welding output and no control. set the Output Control Switch and associated wiring. See the
(S2) to the “Machine or Local” Wiring Diagram.
position and control the weld
2. Check the Output Control switch
output with the machine Output
(S2) and associated wiring. See
the Wiring Diagram.

solved, check the remote con-

trol unit or wire feeder and asso- 3. Perform the Main Transformer
ciated control cable. Test.
2. Make certain the remote control 4. Perform the SCR/Diode Rectif-
leads (#75, #76, #77) are not ier Bridge Test.
grounded to the positive welding
output.
3. Make certain the three-phase
input voltage is correct and
matches the machine rating and
the reconnect panel.
CAUTION
216-383-2531 or 1-800-833-9353.
IDEALARC CV-400

F-7 F-7

OUTPUT PROBLEMS
The machine does not have maxi- 1. Make sure the correct three- 1. Check the Output Control (R4).
mum output. phase input voltage is being Normal resistance is 10,000
applied to the machine. ohms. Also check associated
wiring for loose or faulty connec-
2. If remote control is being used,
tions. See the Wiring Diagram.
set the Output Control switch
(S2) to the “Machine or Local” 2. Check the Output Control switch
position and control the weld (S2) and associated wiring. See
output with the machine Output the Wiring Diagram.

solved, check the remote control
Test.
unit or wire feeder and associat-
ed control cable. 4. Perform the SCR/Diode Bridge
Rectifier Test.
Replace.
The machine will not shut off when 1. Make sure the three-phase input 1. Check the input power switch
the power switch is put in the OFF lines are connected correctly to (S1) and associated leads. See
position. the CV-400. the Wiring Diagram.
2. Perform the Input Contactor
Test.
CAUTION
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-
383-2531 or 1-800-833-9353.
IDEALARC CV-400

F-8 F-8


OUTPUT PROBLEMS
The output terminals are always 1. Remove any external leads that 1. Check for an internal short
electrically “hot.” may be connected to the 14 pin between leads #2 and #4. See
amphenol or the terminal strip. the Wiring Diagram.
If the problem disappears, the
2. Remove plug J3 (SCR gate
fault is in the control cable or
leads) from the control board. If
wire feeder.
the problem disappears, the
control board may be faulty.
Replace. If the output terminals

are still electrically “hot,” perform

the SCR/Diode Rectifier
Bridge Test.
3. The snubber board may be
faulty. Check or replace.
CAUTION
216-383-2531 or 1-800-833-9353.
IDEALARC CV-400

F-9 F-9

WELDING PROBLEMS
Poor arc characteristics. 1. Make sure the correct weld pro- 1. Check the output capacitors and
cedures are being used. connections. A capacitor failure
(Electrode, Gas, etc.) is indicated if the small vent plug
on top of a capacitor is raised or
2. Check the welding cables for
blown out.
loose or faulty connections.
WARNING: The liquid elec-
trolyte in these capacitors is
toxic. Avoid contact with any
portion of your body. Clean

up vented electrolyte using
rubber gloves and a water
dampened cloth. Any elec-
trolyte which gets on skin,
clean with soap and water.
Poor arc striking with semiautomat- 1. Make sure the correct weld pro- 1. The control board may be faulty.
ic or automatic wire feeders. cedures are being used.
(Electrode, Gas, etc.)
The welding arc is variable and 1. Check the input voltage at the 1. Perform the SCR/Diode Recti-
sluggish. CV-400, making sure the correct fier Bridge Test.
voltage and all three phases are
being applied to the machine.
Test.
2. Make sure the welding process
is correct for the machine set-
Replace.
tings.
Also make sure cables are sized
correctly for the welding current.
CAUTION
216-383-2531 or 1-800-833-9353.
IDEALARC CV-400

F-10 F-10
CONTROL TRANSFORMER (T2) VOLTAGE TEST

WARNING
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.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353
(WELD).
DESCRIPTION
This procedure will determine if the correct voltage is being applied to the primary of the
control transformer and induced on the secondary winding of the control transformer.
MATERIALS NEEDED
Volt/ohmmeter (Multimeter)
5/16” Nut driver
IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this
manual.)
IDEALARC CV-400

F-11 F-11
CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued)
FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS

TEST PROCEDURE 5. Locate control transformer leads X1 (top)

and X2.
1. Disconnect the main input supply power to

the machine. a. Lead X1 is connected to the input con-
tactor (CR1) coil located on the input side
2. With the 5/16” nut driver, remove the top, of the contactor. See Figure F.1.
case sides, and rear input panel.
b. Lead X2 is spliced into lead #231. See
3. Locate the control transformer (T2) on the the Wiring Diagram. Lead #231 is con-
left side of the input box (facing the back of nected to the power switch (S1). See
the machine). See Figure F.1. Figure F.2.
4. Locate the control transformer primary leads
(H1, H2, H3, etc.). See the Wiring Diagram.
NOTE: Unused leads should be taped.
a. Inspect for broken or incorrect connec-
tions.
IDEALARC CV-400

F-12 F-12
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 7. Read the meter for 115VAC.
#231.
a. If 115VAC is present, the control trans-
NOTE: If the main AC input supply voltage former is functioning properly.

varies, the control transformer voltage will

b. If 115VAC is NOT present, go to Step 8.
vary by the same percentage.
8. If 115VAC is not present between leads X1
a. Connect one end of an insulated alligator
and #231, check the spliced connection
clip to the X1 connection at the input con-
between #231 and X2. Test for correct main
tactor (CR1) coil. See Figure F.2.
input supply power to the control transformer
b. Connect the other end of the alligator clip primary windings (H1, H2, H3, etc.). Check
to one of the meter probes. Be sure that the main input supply power hookup to the
neither the alligator clip nor the meter machine. See the Wiring Diagram.
probe touches any metal surfaces.
a. If the correct main input supply power to
c. Connect the other meter probe to the the control transformer primary windings
#231 connection (top lead) at the power is present AND the secondary voltage is
switch. See Figure F.2. not correct, the control transformer may
be faulty. Replace.
d. Apply input power to the CV-400.
IDEALARC CV-400

F-13 F-13
INPUT CONTACTOR TEST
WARNING
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.
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the input contactor is receiving the correct coil voltage and if the con-
tacts are functioning correctly.
MATERIALS NEEDED
5/16” Nut driver
IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this manual.)
External 120VAC supply
IDEALARC CV-400

F-14 F-14
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 the power switch (S1) ON.
1. Disconnect the main input supply power to
the machine. 6. Check for 120VAC at the contactor coil leads.
2. With the 5/16” nut driver, remove the case If the 120VAC is NOT present, with the power
top and the reconnect panel cover. switch (S1) on, check the power switch (S1)
and associated circuitry. See the Wiring
3. Locate the two leads connected to the input Diagram. Also perform the Control
contactor coil, #233 and X1 #232 (top). See Transformer (T2) Voltage Test.
Figure F.3 for location.
If the 120VAC is present and the contactor
4. Connect an AC voltmeter to the leads. does NOT activate, then the input contactor is
faulty. Replace the input contactor.
WARNING
Electric Shock can kill.
• With the input power on, there
are high voltages inside the
machine. Do not reach into
the machine or touch any
internal part of the machine
while the power is on.
IDEALARC CV-400

F-15 F-15
INPUT CONTACTOR TEST (continued)
FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS
APPLY EXTERNAL
120 VAC HERE
X1, #232 (X1, #232 AND #233
LEAD TERMINALS)
0597
0597
LINCOLN ELECTRIC CO.

SA M - 12161 - 61
LINCOLN ELECTRIC CO.
SA M - 12161 - 61
(L3)
(L3)
AH# ACC730 - 8025B

AH# ACC730 - 8025B
W
W
(3186-30J755 18H)
(3186-30J755 18H)
(L2)
(L2)
V
V
LR49598
LR49598
CRI
CRI
(L1)
(L1)
U
U
#233
TEST FOR CONTACT CONTINUITY 4. With the contactor activated, check the continuity
across the contacts. (Zero ohms or very low resis-
1. Disconnect the main input supply power to the tance is normal.) See Figure F.4. If the resistance
machine. is high, the input contactor is faulty. Replace the
2. Remove the two leads connected to the input con- input contactor.
tactor coil, #233 and X1/#232. See Figure F.4 for 5. When the contactor is NOT activated, the resistance
location. should be infinite or very high across the contacts.

3. Using the external 120VAC supply, apply 120VAC to If the resistance is low, the input contactor is faulty.
the terminals of the input contactor coil. If the con- Replace the input contactor.
tactor does NOT activate, the input contactor is
faulty. Replace the input contactor.
IDEALARC CV-400

F-16 F-16
MAIN TRANSFORMER (T1) VOLTAGE TEST
WARNING
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will determine if the correct voltages are being applied to the primary windings of the
Main Transformer (T1) and induced on the secondary winding, auxiliary windings, and phase
angle windings.
MATERIALS NEEDED
5/16” Nut driver
IDEALARC CV-400 wiring diagram (See the Electrical Diagrams section of manual.)
IDEALARC CV-400

F-17 F-17
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. 5. Connect main input supply power to the
machine.
2. Disconnect main input supply power from
the machine. 6. Set the ON/OFF power switch to ON.
3. With the 5/16” nut driver, remove the case a. Make sure the input contactor (CR1)
top and sides and the reconnect panel energizes and the fan runs.
cover.
7. Test with an AC voltmeter for proper main
4. Inspect the input contactor, reconnect input supply voltage to the line side of the
panel, and primary leads to the main trans- input contactor (CR1). See the Wiring
former for loose or faulty connections. See Diagram.
Figure F.5.
a. L1 to L2.
a. Confirm that the reconnect panel is
b. L2 to L3.
connected properly for the three-phase
main input power supplied to the c. L1 to L3.
machine. See the reconnect panel
connection diagram located on the
inside of the input box assembly
access door.
IDEALARC CV-400

F-18 F-18
FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS

8. Read the meter. 11. Test with an AC voltmeter for approximate-

ly 42VAC across each of the three main
a. If proper voltage is present for all three
secondary start leads located at the
phases, proper main input supply volt-
SCR/Diode Rectifier Bridge. Remove the
age is being supplied.

red insulating paint to achieve good con-

b. If proper voltage is not present in any tact if necessary. See Figure F.6. See the
or all of the three phases, check input Wiring Diagram.
fuses and leads.
a. If one or more of the above voltage
9. Test with an AC voltmeter for proper main tests are incorrect, check for loose or
input supply voltage from the output side of faulty connections.
the input contactor (CR1). See the Wiring
b. If the connections are good, then the
Diagram and Figure F.5.
main transformer may be faulty. Re-
a. T1 to T2. place the main transformer.
b. T2 to T3.
c. T1 to T3.
10. Read the meter.
a. If proper voltage is present for all three
phases, the input contactor is working

properly.
b. If the proper voltage is not present for
any or all of the three phases, the input
contactor may be faulty. Replace the
input contactor.
IDEALARC CV-400

F-19 F-19
FIGURE F.7 – PHASE ANGLE WINDINGS TEST POINTS AND TERMINAL STRIP LOCATION
21
4
2
14-PIN AMPHENOL
BLANK
31
32 K=42
A=32 J=31
75
B=GND I=41
76
77 L N
C=2 H=21
D=4 G=75
E=77 F=76
M
12. Test for 115VAC between leads #31 and 13. Test with an AC voltmeter for 21VAC for
#32 on the terminal strip. Also test for each phase angle winding at plug P1 on
42VAC between pin K (lead #42) and pin I the control board as shown in Figure F.8
(lead 41) in the 14-pin amphenol. See and the accompanying table.
Figure F.7.
NOTE: If the main input supply voltage
a. Remove the sheet metal screws from varies, the main transformer voltages will
the control box cover with the 5/16” vary proportionately.
nut driver and flip the cover down. It
a. If the voltage is low, remove plug P1
does not have to be completely
and recheck the voltage for 21VAC. If
removed to perform the tests.
the reading is normal, the control board
b. If the above voltage checks are incor- may be faulty. Replace the control
rect, check for loose or faulty wiring. board.
Check continuity.
b. If one or more of the voltage tests are
c. If the wiring is good, then the main incorrect, check for loose or faulty
transformer may be faulty. Replace the wiring.
main transformer.
c. If the wiring is good, then the main
transformer may be faulty. Replace the
main transformer.
IDEALARC CV-400

F-20 F-20
FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION
G2629-[ ] CV-400/CV-500-I CONTROL

#203
#204
Plug P3 #202 #201
Plug P1
Plug P1 PHASE ANGLE WINDING VOLTAGES

From Lead # To Lead # Expected VAC
201 204 21 VAC
202 204 21 VAC
203 204 21 VAC

IDEALARC CV-400

F-21 F-21
STATIC SCR/DIODE RECTIFIER BRIDGE TEST
WARNING
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).
DESCRIPTION
This test will help determine if an SCR or diode is shorted or “leaky.” See the Machine
Waveform Section in this manual for normal and abnormal output waveforms.
MATERIALS NEEDED
Analog Volt/ohmmeter (Multimeter)
5/16” Nut driver
9/16” Wrench
IDEALARC CV-400

F-22 F-22
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 P5
Plug P3
#204
#202 #201
Plug P1 M15370-[ ] SNUBBER
TEST PROCEDURE
1. Disconnect the main input supply power to 5. Locate and remove molex plug P5 from the
the machine. snubber board. See Figure F.9.
2. With the 5/16” nut driver, remove the case 6. Locate and remove lead #204 from resistor
top and sides. R2 (7.5 ohms, 100 watts). See Figure F.14.
3. Disconnect the welding cables from the 7. Using the 9/16” wrench, remove the positive
welding output terminals. capacitor strap lead and small lead terminal
from the rectifier plate and output shunt junc-
4. Locate and remove molex plug P3 from the
tion. See Figure F.10.
control board. See Figure F.9.
FIGURE F.10 – CAPACITOR STRAP LEAD CONNECTIONS
POSITIVE
CAPACITOR
STRAP LEAD
SMALL LEAD
TERMINAL
IDEALARC CV-400

F-23 F-23
STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)

FIGURE F.11 – HEAT SINK AND SCR TEST POINTS
SCR
ANODE
REMOVE ANY
INSULATING
PAINT
CATHODE (SCR)
8. Remove any red insulating paint from the a. Reverse the meter leads and measure
heat sink test points. See Figure F.11. the resistance from cathode (+probe)
to anode (-probe) of diode D1. The
NOTE: Do not disassemble the heat sink.
resistance should be high. See Figure
9. Measure the resistance from the anode to F.11.
the cathode of SCR 1 using an analog
b. If a low resistance is measured in both
volt/ohmmeter (multimeter) set at R x 1000

meter polarities, diode D1 is shorted.
scale. See Figure F.11.
Replace diode D1.
a. Reverse the meter leads and measure
c. If a high resistance is measured in both
the resistance from the cathode to the
meter polarities, diode D1 is open.
anode of SCR 1. See Figure F.11.
Replace diode D1.
b. If a low resistance is measured in
12. Test diodes D2, D3 and D4 for proper oper-
either meter polarity, SCR 1 is faulty.
ation using the same procedure described
Replace SCR 1.
in Step 11.
10. Test the resistance of SCR 2 and SCR 3
13. Reconnect all leads and molex plugs.
using the same procedure described in
Step 9. 14. If this test did not identify the problem or to
further test the SCRs, go to the Active
11. Measure the resistance of diode D1 from
SCR Test.
anode (+probe) to cathode (-probe) using
an analog ohmmeter set at R x 1000 scale.
The resistance should be low. See Figure
F.11.
IDEALARC CV-400

F-24 F-24
ACTIVE SCR TEST
WARNING
trical shock, please observe all safety notes and precautions detailed throughout this manu-
al.
DESCRIPTION
This test will help determine if the device can be gated ON and conduct current from anode
to cathode.
MATERIALS NEEDED
An SCR tester as specified in this procedure.
5/16” Nut driver
9/16” Wrench
IDEALARC CV-400

F-25 F-25
ACTIVE SCR TEST (continued)
FIGURE F.12 – CONTROL BOARD PLUG FIGURE F.13 – SNUBBER BOARD

P1 AND P3 LOCATIONS PLUG P5 LOCATION
G2629-[ ] CV-400/CV-500-I CONTROL
#203 Plug P5
Plug P3
#204
#202 #201
Plug P1 M15370-[ ] SNUBBER
FIGURE F.14 – RESISTOR R2 LOCATION

TEST PROCEDURE
1. Disconnect the main input supply power to 5. Locate and remove molex plug P5 from the
the machine. snubber board. See Figure F.13.
2. With the 5/16” nut driver, remove the case 6. Locate and remove lead #204 from resistor
top and sides. Remove the screws holding R2 (7.5 ohms, 100 Watts). See Figure F.14.
the front panel and lower the panel.

7. Using 9/16” wrench, remove the positive
3. Disconnect the welding cables from the capacitor strap lead and small lead terminal
welding output terminals. from the positive rectifier plate and output
shunt junction. See Figure F.10.
4. Locate and remove molex plug P3 from the
control board. See Figure F.12.
IDEALARC CV-400

F-26 F-26
FIGURE F.15 – HEAT SINK TEST POINTS
SCR
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 CV-400

F-27 F-27

FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
9. Construct the circuit shown in Figure F.16. NOTE: Be sure the battery is function-
One 6-volt lantern battery can be used., Set ing properly. A low battery can affect the
voltmeter scale low, at approximately 0-5 results of the test. Repeat Battery Test
volts or 0-10 volts. Procedure in Step 10 if needed.
10. Test the voltage level of the battery. Short 16. Open switch SW-1.
leads (A) and (C). Close switch SW-1.
17. Reconnect the tester leads. See Figure F.16.
Battery voltage should be 4.5 volts or higher.
If lower, replace the battery. a. Connect tester lead (A) to the cathode.
11. Connect the tester to the SCR 1 as shown in b. Connect tester lead (C) to the anode.
Figure F.16.
c. Disconnect test lead (G) from the gate.

a. Connect tester lead (A) to the anode.
18. Close switch SW-1.
b. Connect tester lead (C) to the cathode.
19. Read meter for zero voltage.
c. Connect tester lead (G) to the gate.
a. If the voltage is zero, the SCR is func-
12. Close switch SW-1. tioning.
NOTE: Switch SW-2 should be open. b. If the voltage is higher than zero, the
SCR is shorted.
13. Read meter for zero voltage.
20. Perform the Active Test Procedure outlined
a. If the voltage reading is higher than zero,
in Steps 11-19 for SCRs 2 and 3.
the SCR is shorted.
21. Replace all SCR assemblies that do not pass
14. Close or keep closed switch SW-1.
the above tests.
15. Close switch SW-2 for 2 seconds. Release
22. Replace all molex plugs onto the control
and read meter.
board and snubber board. Reconnect posi-
a. If the voltage is 3-6 volts while the switch tive capacitor lead and small lead terminal.
is closed and after the switch is open,
23. Reconnect lead #204 to resistor R2.
the SCR is functioning.
b. If the voltage is 3-6 volts only when the
switch is closed or if there is no voltage
when the switch is closed, the SCR is
defective.
IDEALARC CV-400

F-28 F-28
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM
MAXIMUM OUTPUT SETTING – NO LOAD
CH1
0 volts
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.
Note: Scope probes connected at
machine output terminals: (+) probe
to positive terminal, (-) probe to neg-
ative terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....2 ms/Div.
Coupling ............................DC
Trigger .........................Internal
IDEALARC CV-400

F-29 F-29
TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
CH1
0 volts
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. The machine was loaded with

a resistance grid bank. The CV-400
meters read 400 amps at 36 VDC.
ative terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling ............................DC
IDEALARC CV-400

F-30 F-30
TYPICAL SCR GATE VOLTAGE WAVEFORM
MAXIMUM OUTPUT SETTING – NO LOAD
CH1
0 volts
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.
SCR gate and cathode: (+) probe to
gate, (-) probe to cathode.
SCOPE SETTINGS
Volts/Div.......................2V/Div.
Coupling ............................DC
IDEALARC CV-400

F-31 F-31
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED
ONE OUTPUT SCR NOT FUNCTIONING
CH1
0 volts
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. Each
vertical division represents 20 volts
and each horizontal division repre-
sents 5 milliseconds in time. The
machine was loaded with a resis-
tance grid bank. The CV-400 meters
read 400 amps at 36 VDC.
ative terminal.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Coupling ............................DC
IDEALARC CV-400

F-32 F-32
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in inspecting, cleaning, and replacing the input
contactor.
MATERIALS NEEDED
Phillips head screwdriver
5/16” Socket wrench
Flat head screw driver
Low pressure air source
IDEALARC CV-400

F-33 F-33
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 CONTACTOR REPLACEMENT

1. Remove the main input supply power to the PROCEDURE
machine and remove the input access panel. 1. Disconnect main input supply power to the
2. Locate and get access to the input contac- machine.
tor (CR1) in the input box. See Figure F.17. 2. Locate and get access to the input contac-
3. Remove the input contactor cover plate tor (CR1) in the input box. See Figure F.17.
using a phillips head screwdriver. 3. Disconnect the main input supply power
leads L1, L2, and L3 to the input contactor.
WARNING Remove the control transformer primary
leads H1, H2 or H3 (dependent on input volt-

Do not apply input power to age) from L1 and L3 terminals on the input
the machine with the input side of the contactor.
contactor cover plate re-
moved. 4. Using the 7/16” socket wrench, disconnect
the output leads T1, T2, and T3 from the
input contactor. (Label the leads.)
5. Identify and label the leads connected to the
4. Blow out any dirt or dust in or around the input contactor coil. See the Wiring
contacts with a low pressure air stream. Diagram.
5. Inspect the contacts for signs of excessive 6. Disconnect the leads from the input contac-
wear, pitting, or contacts fused (stuck) tor coil (leads X1, #232 and #233). See the
together. Wiring Diagram.
a. If any of these conditions are present, 7. Remove the three self-tapping mounting
replace the input contactor assembly. screws using a 5/16” socket wrench. See
Figure F.17.
6. Replace the input contactor cover plate.
8. Remove the input contactor.
9. Insert the replacement input contactor and
install it following the procedures in reverse
order.
NOTE: Be sure to reconnect all leads correctly.
IDEALARC CV-400

F-34 F-34
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in gaining access to the fan blade and fan
motor for maintenance or replacement.
MATERIALS NEEDED
5/16” Nut driver
3/8” Wrench
Allen head type wrench
IDEALARC CV-400

F-35 F-35
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 5. Remove the four mounting nuts and associ-
machine. ated flat and lock washers that hold the
motor to the mounting bracket. See Figure

2. Using the 5/16” nut driver, remove the case
F.18.
top and sides.
6. Carefully remove the fan motor.
3. The fan blade can be removed using the
Allen head wrench. 7. To replace the fan motor, mount the motor to
its mounting bracket using the four nut and
NOTE: You may need to loosen the
associated flat and lock washers.
machine case back to gain clearance to
remove the fan. See Figure F.18. 8. Resplice any motor leads cut for removal.
Soldering the wires is recommended.
4. If the fan motor is to be removed, the leads
to the motor must be disconnected. This 9. Reattach the fan blade, if it was removed
will require cutting the wires or “breaking the earlier, using the Allen head wrench to
splice.” tighten it to the motor shaft.
10. Install the case top and sides.
IDEALARC CV-400

F-36 F-36
SCR/DIODE RECTIFIER ASSEMBLY

REMOVAL AND REPLACEMENT
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in the removal and replacement of the SCR/
diode assembly.
MATERIALS NEEDED
5/16” Nut driver
7/16” Wrench
1/2” Wrench
9/16” Wrench
3/8” Wrench
Slot head screw driver
1/2” Socket and extension
IDEALARC CV-400

F-37 F-37
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 assembly removal. Clear any necessary
machine. leads that might hinder removal.
2. With the 5/16” nut driver, remove the case 12. For reassembly, carefully place the SCR/
top and sides. diode assembly into position on the mount-
ing bracket and reinstall the washers and
3. Remove the glastic stiffeners (one on right nuts. Tighten the front panel to base if it was
side-two on left side). See Figure F.19. loosened earlier.
4. Remove lead #220 from the right side of the 13. Replace and tighten the four nuts and lock-
negative heat sink plate. washers that hold the SCR/diode assembly
5. Remove the positive capacitor lead and to the mounting brackets.
shunt from the positive heat sink plate. See
14. Reattach the three heavy aluminum sec-

Figure F.19. ondary leads to the SCR finned heat sinks.

6. Remove the choke and negative capacitor Apply a thin coating of Dow Corning 340
leads from the left side of the negative heat heat sink compound (Lincoln E1868) to con-
sink plate. See Figure F.19. nection points.
7. Remove the gate leads from the control 15. Connect the green ground lead to the front
board (plug P3). panel, lead #225 to the negative output lead,
and lead #224 to the positive output lead.
8. Remove plug P5 from the snubber board.
Also remove lead #224 from the positive 16. Connect plug P5 to the snubber board and
output lead. Remove lead #225 from the plug P3 to the control board.
negative output lead. Remove the green 17. Connect the choke and negative capacitor
ground lead from the front panel. lead to the left side of the negative heat sink
9. Remove the three heavy aluminum sec- plate. See Figure F.19. Apply a thin coating
ondary leads from the SCR finned heat sinks. of Dow Corning 340 heat sink compound
(Lincoln E1868) to connection points.
10. Remove the four nuts and associated wash-
ers that hold the SCR/diode assembly to the 18. Connect the positive capacitor lead and
shunt to the positive heat sink plate. See
mounting brackets.
Figure F.19.
11. Carefully lift and remove the SCR/diode heat
sink assembly from the machine. Note: It 19. Install the glastic stiffeners to the left and
may be necessary to loosen the four sheet right sides. See Figure F.19. Apply a thin
metal screws that hold the front panel to the coating of Dow Corning 340 heat sink com-
base. Carefully lift and pull out the front pound (Lincoln E1868) to connection points.
panel to allow clearance for SCR/diode 20. Install the case top and sides.
IDEALARC CV-400

F-38 F-38
SCR REMOVAL AND REPLACEMENT
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in removing the SCRs from the output rectifier
heat sink for maintenance or replacement.
MATERIALS NEEDED
NO.000 Fine Steel Wool
Penetrox A-13 (Lincoln E2529) or Penetrox A
7/16” Open end wrench
Allen head type wrenches
IDEALARC CV-400

F-39 F-39
SCR REMOVAL AND REPLACEMENT (continued)

FIGURE F.20 – SCR DETAILS
SPECIAL INSTRUCTIONS
NOTE: Before disassembling the existing recti- 5. Clean the area on the heat sink around the
fier, note toward which heat sink the outer metal SCR mounting surface, using a putty knife or
ring of the power SCR is mounted. Also, note similar tool. DO NOT SCRATCH THE SCR
the positioning of the gate lead of the SCR. MOUNTING SURFACE.
Failure to reinstall the new SCR in the same ori-
6. Polish each heat sink’s mounting surface
entation as the original may result in subsequent
using NO. 000 fine steel wool. Wipe surface
damage to the new SCR and other components
clean with a lint-free cloth or paper towel.
of the welder. See Figure F.20.
7. Inspect the mounting surfaces of each new
CAUTION SCR.
a. Remove all burrs and wipe clean. Do

The unclamping and clamping procedure out- not use steel wool or any abrasive
lined below is critical for the prevention of inter- cleanser on the SCR mounting surfaces.
nal SCR damage. Failure to follow this proce-
8. Apply a thin (0.001” to 0.003”) layer of PEN-
dure may result in subsequent damage of the
ETROX A-13 (Lincoln Electric #E2529) or
SCR. Handle all SCRs with care.
PENETROX A, heat sink compound, to each
heat sink’s SCR mounting surface.
PROCEDURE a. Care must be used to prevent foreign
material contamination of the SCR to
heat sink junction.
1. Remove the main input supply power to the 9. Place the new SCR between the heat sinks.
machine. Be sure that the outer metal ring of the SCR
2. Perform the SCR/Diode Rectifier is facing toward the same heat sink as the
Assembly Removal and Replacement pro- old SCR’s metal ring. Be sure that the roll
cedure. pin of the heat sink engages the “hole” in the
SCR. The SCR contact surfaces must sit flat

3. Alternately loosen nuts 1/2 turn each until against both heat sink surfaces.
heat sinks are loose. Remove nuts and leaf
spring. IT IS RECOMMENDED THAT NEW
HARDWARE, LEAF SPRING AND HOUSING
BE USED FOR REASSEMBLY.
4. Remove the old SCR.
IDEALARC CV-400

F-40 F-40

FIGURE F.21 – 1/2” WIDE LEAF SPRING FIGURE F.22 – CLAMP ASSEMBLY
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. The two
different designs can be identified by the size of
the leaf spring. One design uses a 1/2 inch wide
leaf spring, and the other uses a 5/8 inch wide
spring. The different designs require different
assembly and clamping procedures. The assem-
bly procedure will be different depending upon the
thread on the cap screws. A 1/4-28 thread
requires a different tightening procedure than a
1/4-20 thread.
PROCEDURE FOR THE 1/2 INCH WIDE
SPRING
1. Place a piece of sleeving around each cap screw.
2. Insert cap screws through the leaf spring. Orient
the leaf spring so that its ends are curved upward
toward the cap screw heads. See Figure F.21.
Pressing on the cap screw heads should produce
a “rocking” motion of the spring in its housing. If
the spring does NOT rock, it is installed upside
down. Remove the spring and turn it over. Check
for “rocking” motion. See Figure F.21.
3. Insert cap screws and leaf spring into the plastic
housing.
4. Insert clamp assembly through heat sinks. Install
nuts. Tighten clamp nuts equally on cap screws
until finger tight. (See Figure F.22. Heat sinks may

not be exactly as pictured.)
5. Reinspect the SCR for proper seating.
IDEALARC CV-400

F-41 F-41
CLAMPING PROCEDURE CLAMPING PROCEDURE

FOR 1/4-28 CAP SCREWS FOR 1/4-20 CAP SCREWS
NOTE: This procedure can only be used with NOTE: This procedure can only be used with
1/4-28 cap screws. 1/4-20 cap screws.
Do not use cap screws with any other type Do not use cap screws with any other type
thread or new SCR will be damaged. thread or new SCR will be damaged.
Do not over tighten cap screws. The leaf spring Do not over tighten cap screws. The leaf spring
will apply the required clamping force to the will apply the required clamping force to the
SCR. SCR.
1. Do not turn the nuts. While holding the nuts 1. Do not turn the nuts. While holding the nuts
stationary, turn the cap screws only with the stationary, turn the cap screws only with the
following procedure. following procedure.

2. Tighten first cap screw 1/4 turn. 2. Tighten first cap screw 1/4 turn.
3. Tighten second cap screw 1/2 turn. 3. Tighten second cap screw 1/2 turn.
5. Tighten second cap screw 1/2 turn. 5. Tighten second cap screw 1/4 turn. STOP.
6. Tighten first cap screw 1/4 turn. Stop. 6. Assembly now has the proper clamping
force.
7. Assembly now has the proper clamping
force. 7. Perform the Active SCR Test.
8. Perform the Active SCR Test.
IDEALARC CV-400

F-42 F-42

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.
2. Insert cap screws through the leaf spring.
The leaf spring is flat so the orientation of the
leaf spring does not matter.
3. Place the steel pressure pad in the housing
with the 1/8 inch wide standoff facing up.
See Figure F.23.
4. Insert cap screws and leaf spring into plastic
housing being sure that the steel pressure
pad remains in position. Pressing on the cap

screw heads should produce a rocking action
of the spring in its housing.
5. Insert the clamp assembly through the heat
sinks. Install nuts. Tighten the clamp nuts
equally on the cap screws until finger tight.
Be sure that the leaf spring is not cocked in
the housing. See Figure F.24. Heat sinks
may not be exactly as pictured.
6. Reinspect the SCR for proper seating.
IDEALARC CV-400

F-43 F-43
CLAMPING PROCEDURE CLAMPING PROCEDURE

FOR 1/4-28 CAP SCREWS FOR 1/4-20 CAP SCREWS
NOTE: This procedure can only be used with NOTE: This procedure can only be used with
1/4-28 cap screws. 1/4-20 cap screws.
Do not use cap screws with any other type Do not use cap screws with any other type
thread or new SCR will be damaged. thread or new SCR will be damaged.
Do not over tighten cap screws. The leaf spring Do not over tighten cap screws. The leaf spring
will apply the required clamping force to the will apply the required clamping force to the
SCR. SCR.
1. Do not turn the nuts. While holding the nuts 1. Do not turn the nuts. While holding the nuts
stationary, turn the cap screws only with the stationary, turn the cap screws only with the
following procedure. following procedure.

7. Tighten second cap screw 1/4 turn. STOP. 7. Tighten second cap screw 1/8 turn. STOP.
8. Assembly now has the proper clamping 8. Assembly now has the proper clamping
force. force.
9. Perform the Active SCR Test. 9. Perform the Active SCR Test.
AFTER REPLACING THE SCRs

Follow the steps in the SCR/Diode Rectifier

Removal and Replacement procedure to
reassemble the machine.
IDEALARC CV-400

F-44 F-44
MOUNTING OF STUD TYPE DIODES

TO ALUMINUM HEAT SINKS
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in mounting stud type diodes to the aluminum
heat sinks on the DC-400.
MATERIALS NEEDED
5/16” Nut driver
1/2” Open end wrench
Lincoln E1868 (Dow Corning 340) Heat Sink Compound
“Slip” type torque wrench
No. 000 fine steel wool
IDEALARC CV-400

F-45 F-45
MOUNTING OF STUD TYPE DIODES

TO ALUMINUM HEAT SINKS (continued)
PROCEDURE
1. Remove the main input supply power to the DIODE STUD FOOT- INCH-
machine. SIZE POUNDS POUNDS
2. With the 5/16” nut driver, remove the case 3/4-16 25-27 300-324
top and sides. 3/8-24 10±.5 125+0/-5
1/4-28 22-25
3. Loosen the appropriate diode nut and
remove the diode that is to be replaced.
4. Clean the area on the heat sink around the
diode mounting surface using a putty knife
or similar tool. DO NOT SCRATCH THE
DIODE MOUNTING SURFACE.

5. Polish each heat sink’s mounting surface
using No. 000 fine steel wool. Wipe the sur-
face clean with a lint-free cloth or paper
towel.
6. Inspect the mounting surfaces of each new
diode. Remove all burrs and wipe clean. Do
not use steel wool or any abrasive cleanser
on the diode mounting surface.
7. Apply a thin (0.003” to 0.007”) uniform layer
of E1868 (Dow Corning 340) heat sink com-
pound to the heat sink mounting surface.
a. Do not apply compound to the diode
stud or mounting threads.
b. The diode threads must be clean and

free of defects so that the nut can be fin-
ger tightened before applying torque. A
“slip” type torque wrench must be used
to tighten the diode nut.
8. Tighten the diode nuts to the specifications
in the following table.
a. Start the nuts for diodes with steel studs
by hand and then torque them accord-
ing to the following table.
b. Run the nuts for diodes with copper
studs on all the way by hand then torque
them according to the following table.
c. Turn the nuts a minimum of 1/2 turn
more while torquing.
9. Install the case top and sides.
IDEALARC CV-400

F-46 F-46
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
WARNING
al.
DESCRIPTION
The following procedure will aid the technician in removing the main transformer for mainte-
nance or replacement.
MATERIALS NEEDED
5/16” Nut driver
9/16” Box end wrench
1/2” Box end wrench
3/8” Nut driver or socket wrench

9/16” Deep well socket wrench
IDEALARC CV-400

F-47 F-47
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)

FIGURE F.25 – LIFT BAIL REMOVAL
REMOVAL OF LIFT BAIL 8. Using the 9/16” socket wrench, remove the
four bolts (left and right) mounting the lift bail
1. Remove the main input supply power to the to the transformer top and bottom irons.
machine.
9. Using the 9/16” socket wrench, remove the

2. With the 5/16” nut driver, remove the case four bolts, flat washers, and lock washers
top and sides. mounting the lift bail assembly to the base of
3. Remove the two fiber baffles from the left the machine.
and right sides of the lift bail adjacent to the
main transformer. See Figure F.25. WARNING
4. Remove the two leads (#220 and #204)
from resistor R2 (7.5 ohms, 100 watts). The transformer and choke assembly is now
loose and free to slide or “tip” on the base of the
5. Remove the positive capacitor strap from machine.
the output shunt.
6. Remove the negative capacitor strap from
the negative rectifier plate. 10. Remove the lift bail by lifting straight up and
clear from the machine.
7. Remove the sheet metal screw that holds
the capacitor bank assembly to the case
back. (This should enable the capacitor

bank to be removed with the lift bail assem-
bly.)
IDEALARC CV-400

F-48 F-48
FIGURE F.26 – CHOKE REMOVAL
CHOKE TOP
LEADS "E" IRON
GLASTIC THRU-BOLTS
STIFFENERS (4)
BOTTOM
"E" IRON
REMOVAL OF CHOKE AND TOP

IRON ASSEMBLY
1. Remove the three (two left and one right) 5. Using a hoist, carefully lift the choke and top
glastic stiffeners connecting the negative rec- iron assembly out and clear of the trans-
tifier plate and choke assembly to the main former coils.

transformer thru-bolts. See Figure F.26.
NOTE: The coils may be “stuck” to the top iron
2. Remove the top choke lead from the negative and may require some careful prying to
rectifier plate. dislodge them. Depending upon which
coil(s) are to be replaced, it may be
3. Remove the bottom choke lead from the neg-
advantageous to remove some of the
ative output terminal.
“stuck” coils with the top iron.
4. Using the 9/16” deep well socket wrench,
6. The leads from the coils that are to be
remove the four thru-bolts that clamp the top
removed and/or replaced must be discon-
“E” iron and choke assembly to the bottom
nected. See the Wiring Diagram.
“E” iron. NOTE: for easier reassembly, clean
the threads. When aluminum leads are re-connected, apply a
thin layer of Dow Corning 340 Heat Sink
Compound (Lincoln E1868) to mating surfaces.
IDEALARC CV-400

F-49 F-49
FIGURE F.27 – EPOXY MIX APPLICATION AREAS

REASSEMBLY OF TRANSFORMER
COILS
NOTE: The following procedure describes a
complete replacement of all primary and sec-
ondary transformer coils. 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. Coat the
areas no closer than .38 inches from the top
edge of the iron. See Figure F.27, arrows. Be
sure that none of the epoxy drips onto the
top of the iron assembly where it will meet the
top assembly.
IDEALARC CV-400

F-50 F-50

FIGURE F.28 – COIL LEAD PLACEMENT
MACHINE FRONT
SECONDARY COIL LEADS
PRIMARY COIL LEADS

3. Install the bottom primary coils, one on each of the 7. Place insulation (Lincoln Electric part number
three legs of the bottom iron assembly. The coils S20728) on top of each of the three secondary
must be in correct position (left, center, right). coils. The longer side of the insulation should be
Place the coils so that the leads come out at the placed toward the front of the machine, where the
back of the machine. See Figure F.28 for proper secondary start and finish leads come out. See
positioning. Figure F.29.
4. Place insulation (Lincoln Electric part number 8. Install the three top primary coils, noting which is
S20728) on top of each of the three primary coils. right, left, and center. Leads should come out at
The longer side of the insulation should be placed the back of the machine. See Figure F.28 for prop-
toward the front of the machine. See Figure F.29 er positioning. The coils must be in correct position
for the location of this insulation (left, center, right).
5. Place the three secondary coils on top of the insu- 9. Install the top iron (lamination) and choke assem-
lation installed in Step 4. The leads should come bly. With the 9/16” deep well socket wrench,
out at the front of the machine with the short leads reassemble the four thru-bolts that clamp the top
on top. See F.28 for proper positioning. “E” iron to the bottom “E” iron. Lightly tap on the
top of the iron with a hammer before tightening.

6. Insert shims (Lincoln Electric part number
Tighten the nuts and thru bolts to 19-25 lb-ft.
CI001250 or CI000317) between the secondary
coil sides and the iron assembly on either side of
the legs. See Figure F.29.
FIGURE F.29 – COIL INSULATION
PRIMARY COILS
TOP LEFT TOP CENTER TOP RIGHT
SECONDARY COIL ASSEMBLY

INSULATION
PRIMARY COIL (BOTTOM)

SHIMS
IDEALARC CV-400

F-51 F-51

FIGURE F.30 – PRIMARY THERMOSTAT LOCATION
TOP VIEW
THERMOSTAT
INSULATION
FRONT VIEW
10. Mount the primary thermostat to the lead 11. 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. Hold the thermostat in
place with E2381 (.375” wide) tape. If nec-
essary, after assembly protect the thermo-
stat terminals with E2547 terminal boots.
FIGURE F.31 – SECONDARY LEAD TRIM AND WELD DETAIL
TIG WELD
IDEALARC CV-400

F-52 F-52

REASSEMBLING THE MAIN REASSEMBLE THE LIFT BAIL
TRANSFORMER INTO THE MACHINE 1. Carefully position the lift bail onto the machine
NOTE: The following procedure assumes you have base. Using the 9/16” socket wrench, attach the lift
completely reassembled the transformer coils bail to the base of the machine with four bolts, flat
as described in the procedure above. The washers, and lock washers.
lower iron has remained in place in the 2. Using the 9/16” socket wrench, attach the lift bail to
machine. See Figures F.25 and F.26. the transformer top and bottom irons with four
1. Attach the bottom choke lead to the negative out- bolts.
put terminal. 3. Attach the sheet metal screw that holds the capac-
2. Attach the top choke lead to the negative rectifier itor bank assembly to the case back.
plate. 4. Connect leads #220 and #204 to resistor R2.
5. Connect the negative capacitor strap to the nega-

tive rectifier plate.
6. Connect the positive capacitor strap to the output
shunt and positive rectifier plate.
7. Attach the fiber baffle on the bottom choke lead.
8. Attach the two fiber baffles to the left and right
sides of the lift bail, adjacent to the main trans-
former.
9. Install the machine case top and sides.
NOTE: When aluminum leads are reconnected,
apply a thin layer of Dow Corning 340 Heat Sink
Compound (Lincoln E1868) to the mating surfaces.
IDEALARC CV-400

F-53 F-53
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. OR
• If you repair or replace any electrical components.
INPUT IDLE AMPS AND WATTS

Input Volts/Phase/Hertz Maximum Idle Amps Maximum Idle KW
200/3/60 10.9 1.2
208/3/60 10.5 1.2
220/3/60 9.9 1.2
230/3/60 9.5 1.2

380/3/60 5.8 1.2
400/3/60 5.5 1.2
415/3/60 5.3 1.2
440/3/60 5.0 1.2
460/3/60 4.8 1.2
500/3/60 4.4 1.2
575/3/60 3.8 1.2
200/3/50 19.8 1.2

220/3/50 18.0 1.2
230/3/50 17.2 1.2
380/3/50 10.4 1.2
400/3/50 9.9 1.2
415/3/50 9.5 1.2
440/3/50 9.0 1.2
500/3/50 7.9 1.2
OPEN CIRCUIT VOLTAGES

Test Points Input Hertz Open Circuit Volts
Welding Output Terminals 60 43/47VDC
Welding Ouput Terminals 50 43/47VDC
Auxiliary Output (#31 - #32) 60 114/124VAC

Auxiliary Output (#41 - #42) 60 43.8/47.5VAC

Auxiliary Output (#41 - #42) 50 42.0/45.6VAC

WELDING OUTPUT LOAD TEST

Output Control Setting Amps Volts
Minimum 75 to 150 6 to 11
Maximum 525 more than 41.2
IDEALARC CV-400

F-54

NOTES
IDEALARC CV-400
F-54
G-1 G-1
Return to Master TOC 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

G-2 G-2
ELECTRICAL DIAGRAMS
Wiring Diagram (Codes 10084, 10085, 10086)
H3
DUAL & SINGLE VOLTAGE TO GROUND 230/400 VOLTAGE TO GROUND 380/500 V. TO GROUND 220/380/440 VOLTAGE
UNDER 346 VOLTS N.B. H4
PER NATIONAL (SHOWN CONNECTED PER NATIONAL (SHOWN CONNECTED PER NATIONAL
(SHOWN CONNECTED FOR 220 V.)
(SHOWN CONNECTED ELECTRICAL CODE FOR 230 V.) ELECTRICAL CODE FOR 380 V.) ELECTRICAL CODE
FOR LOW VOLTAGE)
N.B. H3 N.B. H3
TO SUPPLY TO SUPPLY RECONNECT PANEL
RECONNECT PANEL
RECONNECT PANEL
N.B. H3 TO SUPPLY
H2 LINES LINES
LINES
RECONNECT PANEL TO SUPPLY
H2 H2 LINES
X1 L3 L2 L1 L3 L2 L1 H2
X1 X1 L3 L2 L1 TO GROUND
L3 L2 L1
3 9 6 11 X1 11 9 6 PER NATIONAL
W 3
9 5 3 3 18
W W
2 3 ELECTRICAL
2 2 W
V V V 2 10 8 5 CODE
232 1 8 5 232 1 8 4 10
232 1
2 17 V
u
U U 1
U
CR1 4 CR1 7 6 12 CR1 1 16 12 7 4
7 CONTACTOR CONTACTOR CR1
CONTACTOR 233 FLEX LEAD
COILS 233 H1 233 H1

TO PRIMARY CONTACTOR JUMPER
233 H1 COILS
H1 TO PRIMARY COILS
TO PRIMARY T0 PRIMARY COILS
SINGLE VOLTAGE OVER FAN MOTOR

232
345 VOLTS 2A 51 115V
TO GROUND PER CIRCUIT 31 H1 X1
NATIONAL ELECTRICAL
BREAKER 32A CONNECT OR
CODE
THIS CONNECTION
10AMP INSULATE AS
H2 115V
N.B. DOES NOT APPEAR ON CIRCUIT 42
H2 TO SUPPLY 50 SHOWN ON
220/380/440V AND BREAKER H3
H3 LINES 52 INPUT
42 X2
230/400V NACHINES CONNECTION H4
X1 L3 L2 L1
241 2 DIAGRAM 231
3
10 SECONDARY PRIMARY T2 CONTROL
W 11 12 42A
THERMOSTAT
2 TOP S THERMOSTAT
220V 42V TRANSFORMER
V PRIMARY 115V
232 1 N.E. 41
U S
7 8 9 S 41
231
CR1 201 203
AUXILIARY 202 4
CONTACTOR T1 MAIN
COILS CAPACITOR
21V 21V 21V
233 H1 TRANSFORMER 41 DISCHARGE
S
CR4 RELAY
S S 204
BOTTOM 4 5 6
X1 X2 X3
PRIMARY CAPACITOR
SEC 2 SEC 3 SEC
1 DISCHARGE
OPTION
16 17 18
R8
10A 0.5 /50W
F2
SLOW
N.A. BLOW
0.5 /50W
R7
254 204
P5 220 220
1 220 C1 +
2 221 D1 N.C. C2 +
D2 D3 31,000MFD
3 222 D4 C3 + 50V EACH
204
DIODE
4 223 C4 +
RECTIFIER OPTION
J5
5 225 ASSEMBLY SHUNT C5 +
SCR1 SCR2
S CR2 SCR3
+ -
6 224
220 204
GREEN
7 LEAD NOT PRESENT R2 7.5 /100W
8 204 205 206 WITH DIODE OPTION
SNUBBER G3
BOARD G2 204
204
G1
224
P1 P3
1 2 4 3
P2
S3 41 1
21 VOLTMETER 1 205
SWITCH
225 201 2
J3 2 206
225 ELECTRICAL SYMBOLS PER E1537
202 3 3 212
21
4 4 J1 4 220 5 1
N.A. J2
4 6 2
204 5 5 205
3 1 7 3
C6 203 6 4 2 8 4
2 6 206
.0047MFD
2 7 4 PIN 8 PIN
1400V 31 7 213
240 8 J3 J1 J2 & J5
TS2 32 CONTROL BOARD 8 75 CONNECTOR CAVITY
NUMBERING SEQUENCE
(COMPONENT SIDE OF P.C.
BOARD)
L1 TS1 75
OUTPUT
CONTROL BOARD
CHOKE 76 10A NOTES
32 CIRCUIT GROUNDING LEAD
77 BREAKER N.A. CIRCUITRY PRESENT ON
32A CAPACITOR DISCHARGE ONLY.
240
N.B. TAPE UP SEPARATELY
N.F. N.A. TO PROVIDE AT LEAST
212 210 211 213 600 V INSULATION.

210 232 233
42 211
GROUNDING 75
32 31 41 Y N.C. CIRCUITRY PRESENT ON
STUD
R4
42 W 233
DIODE OPTION ONLY.
76 77
2 10K /2W 231
PILOT
4 21 OUTPUT THERMAL N.D. THESE LEADS ARE PRESENT
S2 CONTROL PROTECTION LIGHT WITH METER OPTION ONLY.
77 S1
75 OUTPUT CONTROL LIGHT
GREEN 76 POWER
SWITCH
SWITCH
N.E. 220V WINDING, PLUG
N.D.
AND CIRCUIT BREAKER

224 ARE PRESENT ONLY
205
225 ON CV500-I.
206
224 N.F. 31 AND 32 ARE NOT
AM VM
PRESENT ON EUROPEAN
- - METERS CV500-I
+
+
OPTIONAL
206
12-9-94F
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 CV-400

G-3 G-3
ELECTRICAL DIAGRAMS
Wiring Diagram (Code 10087)

230/460/575V.
H3 (SHOWN CONNECTED FOR 230 V.)
N.B. H4 TO SUPPLY
LINES
H2 RECONNECT PANEL
L3 L2 L1 13
X1 3
9 14
W 15
TO GROUND PER NATIONAL 8 4 5 N.B.
V 2 16
ELECTRICAL CODE 6
17
U 7
18
FAN MOTOR CR1 1
233 CONTACTOR
TO PRIMARY
COILS
T1 MAIN 232 H1
31 CONNECT OR
TRANSFORMER X1
32A INSULATE AS
10AMP H2
42 SHOWN ON 115V
CIRCUIT
AUXILIARY 42
BREAKER INPUT H3
COILS 10
42A 241 2 CONNECTION
H4 X2
11 12
SECONDARY PRIMARY DIAGRAM
115V 42V 231
THERMOSTAT THERMOSTAT
41 T2 CONTROL
7 8 S 9 S 41 TRANSFORMER
201 203
202
TOP 231
PRIMARY 13 14 21V 15
21V 21V
S S 4
204 CAPACITOR
S 41 DISCHARGE
4 5 6 CAPACITOR RELAY
BOTTOM CR4
PRIMARY X1 SEC X2 SEC X3 SEC DISCHARGE
1 2 OPTION
N.A.
16 17 18
R8
10A 0.5 /50W
F2
SLOW
BLOW
0.5 /50W
R7
254 204
C1 +
P5 220 220
C2 +
1 220 31,000 MFD
C3 + 50V EACH
2 221 D1 N.C.
D2 D3
C4 +
3 222 D4
204
DIODE C5 +
4 223
RECTIFIER OPTION
J5 220 204
5 225 ASSEMBLY SHUNT
SCR1 SCR2 SCR3
224 + - R2 7.5 /100W
6
GREEN
7 LEAD NOT PRESENT
8 204 205 206 WITH DIODE OPTION
SNUBBER G3
BOARD G2 204
204
G1
224
P1 P3 ELECTRICAL SYMBOLS PER
1 2 4 3 P2
S3 E1537
41 1
VOLTMETER
21 1 205
SWITCH
225 201 2 5 1
J3 2 206 6 2
225 202 3 3 1 7 3
3 212
4 2 8 4
21
4 4 J1 4 220
N.A. J2 4 PIN 8 PIN
4
204 5 5 205 J3 J1, J2 & J5
C6 203 6 CONNECTOR CAVITY

2 6 206
.0047MFD NUMBERING SEQUENCE
2 7
1400V 31 7 213 (COMPONENT SIDE OF P.C.
240 8 BOARD)
TS2 32 CONTROL BOARD 8 75
NOTES
N.A. CIRCUITRY PRESENT ON
L1 TS1 75 CAPACITOR DISCHARGE
OUTPUT ONLY.
CONTROL BOARD
CHOKE 76 10A
32 CIRCUIT GROUNDING LEAD N.B. TAPE UP SEPARATELY
77 BREAKER
TO PROVIDE AT LEAST
32A 600 V INSULATION.
240
N.C. CIRCUIT PRESENT ON

N.A.
DIODE OPTION ONLY.
212 210 211 213 210 232 233
42 211
GROUNDING 75 N.D. THESE LEADS ARE
32 31 41 Y
STUD
R4
42 W 233
PRESENT WITH METER
76 77 OPTION ONLY.
2 10K /2W 231
PILOT
4 21 OUTPUT THERMAL
S2 CONTROL PROTECTION LIGHT
77 S1
75 OUTPUT CONTROL LIGHT
GREEN 76 POWER
SWITCH SWITCH
N.D.
224
205
225
206
224
12-9-94F
AM VM
- - METERS
+
+
OPTIONAL
206 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 CV-400

G-4 G-4
ELECTRICAL DIAGRAMS
Control PC Board (G2629-1) Layout
ITEM REQ’D. PART No. IDENTIFICATION

G2629-1 CV400 / CV500-I CONTROL D48
D49 R26
M QU1
C23 D10
C7
R135
D23
D13
R146
R145
R142
R139
R137
R134
R140
R89
R88
C36
R17
Q8
D74
Q2
DZ5
X5 D16
R64
R63
C35 R29
SCR1 D7
C1
N R14
R141 R1
C4
D4
D50
D80
D79
D63
H
R143
C20
C46
C31
R90
X3
D47
D37
R112 D1 R11
R10
R4
R160 R20
C10 R166 DZ1
C39
E R163 R169 R7
R148
D65
R115
D62
D83
R192
R193
R176
R154
R175
R153
R155
C15
R83
R95
R98
R99
R60
R62
R61
R57
R94
R91
R93
R58
R59
R27
C22
D40
D55
QU2
C44
C41
DZ10
DZ9
D11
D14 C8
C40 R18
D17 R30
D A
C30
R152
DZ12
X4 X2 X1 OCI1 D8
SCR2
DZ13
C2
R113
R15
R2
D5
D81
C5
R191 R40
I
R190 D2 R12
R86
D76
D78
D22
R144
R5
D75
D77
R41 R161 R21

C11 R167 DZ2
R82
R151
C19 R76 R164 R170 R8

C24
D51 D31 D66
R56
R38
C43
D52 R124 R149 D12 R28

R39 G QU3
D32 D33 D15
R35
D42 D18 C9
R51
R19
R114
R71
D41 R50 R37 D67 R31

R158 R159 R36
R150 SCR3 D9
R157 C17 R43 C3
R156 K R16
R77 R70 R3
C38
C6
D6
R75 J
D3 R13
C37 R87
DZ14
D35
C45
R6
D71
L
R81
R79
R78
R162 R22
D82
D72
D73
R189
R188
R187
R186
R185
R184
R183
R182
R181
R180
R179
R178
R177
R174
R173
R172
D19
D20
D21
D70
D68
D69
C18 D34 C12 R168 DZ3
R165 R171 R9
J2 J1 J3
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate
your factory warranty. 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.
IDEALARC CV-400

promise 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.
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 com-
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board NOTE:
G-5
220 R193 R192

10K
R140
RECTIFIER BRIDGE 1.82K 2.00K
CAPACITOR
J1 D19
R141
4 J2 VOLTAGE BUFFER OVER-VOLTAGE 201
6 1
203
600V
+15V
X4 8
PROTECTION
1K 5W
J1 D20 475K
TL431 REF
7-18-97J
3 C45 R99 D10
202 +15V
L 9148
9 6 68
H
R112
600V .0047 5W
POWER UP
R156
1400V 8 6 SCR1
J1
13.7K D42 X2 R98 D65 J3
D21
201 2
OUTPUT CLAMP 10
10K X2
7
1 G1
600V 5
R157 75.0 75.0 4A D13 D16
R142
D22 400V
10K
R20
R144
10K 13.7K 1.00K

R2
R3
R1
R10
D80 D41 75.0 D1 475
R190
203
R158
R95
1.50K 22.1K 1.00K R191 D40

13 4.32K
R166
202 R155 267
14
C39 221K X3 R146
R14
47 12 -10V 267
2.67K
R159
201 35V 1.50K -10V

D63 DZ1 100K
C35 50K
R11
2.67K C10
R4
10K
R160
R26
R163
R134 562 562
R143
10K R145 Q8 QU1

.33 50V 15.0K D CW
D23 2N4857 2N6027 D7
15V 1W C7
R135
221K
200
R169
C1
4.7 D4
R29
S C36 C4 100K
35V
R7
R17
2.67K .15 4.75K
4.7
R137
D74 100K 35V 200V

C23
+15V SUPPLY .15 1 0 0 V 33.2K
D R88 202
2.70 2.5W
R41 X5 R89 M
IN OUT
D68 D69 D70 C40 475K
9 D11
DZ9 C41
I
R113
GND 4.7 68
600V 600V 600V 150 17V 8 5W
X3 SCR2
ELECTRICAL DIAGRAMS
50V 5W 35V
D66 J3
10
+15V 2 G2
D47 CONTROL 75.0 75.0 D14 D17
D71 D72 D73 4A 400V
CURRENT
R154
R21
1.00K
R194
R195
R196
R86
2.70 2.5W 2.67K C46 75.0 D2 475
600V 600V 600V
SWITCH +15V
0.1 D48
R59
R40 100K D79 50V

15.0K
R139
R167
267
-10V SUPPLY C43
+15V +15V
150
CURRENT
R148
R15
250 A R57 D51 267
5
50V 10K
E
10W
AMP 100K X3
7 DZ2 100K C11
R12
R83 2.67K 50K
R5
R27
R164
R161
OFFSET C15 562 562
IDEALARC CV-400
CW 6
QU2
R38
+15V CW
TRIM 1.8 10K 2N6027 D8
R64
DZ10 50K D55 D37
D50 15V 1W C8
10V 20V
R58
2.21K C20 200
R170
5W 1.8 C2
20V 4.7 D5
R30
221K C5 100K
R37
G D49 35V
R18
10K 2.67K .15 4.75K
R8
R91
-10V
R90
15.0K 200V
K 10K CURRENT 1.00K
J3
R63
J2 D31
LIMITER
3 204
R124
205 5 R36 2
10
C38
J2 150 X1 R56 1
.047 8 3 X3 100K
1
METERS 100K X2
R43
100V 150 C24 3

L 9 1 R175
4.7 D83
J2
35V 2
206 2 R35 R39
R93
C22 4.75K
START
J2 R62 203
475 43.2K
R94
C37 15.0K
221K
CURRENT PRESET
6 1.8
METERS
.047
+15V 20V
R176
Control PC Board (G2629-1) Schematic
100V 10K
AMP D12
J
R114
68
5W SCR3
R61
D67 J3
2.21K
4 G3
J1
1.00K D15 D18
75.0 75.0
R60
4 75.0 4A 400V
4
R22
1.00K
R87
R197
R198
R199
D3 475
J1
OUTPUT PILOT CIRCUIT 56
R81
J2
7 3
2 212
R168
DZ14 +t 267
1.5K 15W D52
24V C19
R16
R172 5W R149 4.75K 267
R82
+15V
R115
DZ13 1.82K
J1 243 1.5K 15W
D82 DZ3 100K C12
R13
2.67K 50K
R6
R28
R162
R165
240 8 R173 R150 R152 562 562
OCI1 -10V
243 R177-R189=68.1K 1/4W D75 100 QU3

CNY17-3 CW
15V 2N6027 D9
5W
1 5
15V 1W C9
R174 +15V
D81 200
R171
DZ12
243
D77 D76
6.2V MAX. OUTPUT C3
4.7 D6
R177
R178
R179
R180
R182
R184
R185
R187
R188
R189
R186
R31
R183
1W
R181
C6 100K
BUFFER 35V
R19
2 6 4 2.67K .15 4.75K
R9
160 10K D34
R151
100K 200V
R71
100 56
10W 12 J2
CW
D62
R153
X1 R75 R78 7
14 213
J1 D78
+t
C18
41 1 13 D35
C44
R70
12.1K
4.7
+15V
35V
N D
+15V -10V 1.50K Q2
R77
+15V 15A
60V
J1 -10V 100K
R51
5 G
204 S
D33
4 4 4 12 56 J2
X2 R76 R79 8
14 75
DZ5
+t
267 15V 1 W
C30 X1 X2 X3 C31 13 C17 FIRING CIRCUIT
2 D32
LM224 LM224 LM224
MIN. OUTPUT
1
X1
3
2.21K
BUFFER
11 11 11
R50
-10V
L 9148
6
7
X1
5
-10V
G-5
G-6 G-6
ELECTRICAL DIAGRAMS
Snubber PC Board (M15370-3) Layout
R1
R3
TP2
TP3
J5
R2
TP1
C3
C1
C2
TP4
C4
TP6
TP5
C5
M15370-3 SNUBBER
ITEM REQD PART NO. DESCRIPTION

C1,C2,C3 3 T11577-68 .68/400
C4,C5 2 T11577-46 .05/600
R1,R2,R3 3 T12733-10 10 2W
TP1,TP2,TP3 3 T13640-12 38J
TP4,TP5 2 T13640-18 160J
TP6 1 T13640-16 80J
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate
your factory warranty. 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.
IDEALARC CV-400

promise 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.
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 com-
Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board NOTE:
G-7
S 19687
221 204 222 223 220 225 224
2 8 3 4 1 5 7 6
J5 J5 J5 J5 J5 J5 J5 J5
C1 C2 C3 TP4
.68 .68 .68 320V
C4
ELECTRICAL DIAGRAMS
400V 400V 400V 160J

.05
600V
IDEALARC CV-400
TP6 C5 TP5
5W 5W 5W
.05
R2
R3
150V 320V
R1
10 10 10
80J 600V 160J
Snubber PC Board (M15370-3) Schematic
TP1 TP2
130V 130V
38J 38J

TP3
130V
38J GENERAL INFORMATION
ELECTRICAL SYMBOLS PER E1537
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS,1/4 WATT (UNLESS OTHERWISE SPECIFIED)
DIODES = 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED)
OP AMPS = LM124 (UNLESS OTHERWISE SPECIFIED)
= COMMON CONNECTION
FILENAME: S19687_3EA
UNLESS OTHERWISE SPECIFIED TOLERANCE EQUIP.
Ch’ge.Sht.No.
IDEALARC DC400
ON HOLES SIZES PER E-2056 THE LINCOLN ELECTRIC CO. TYPE
ON 2 PLACE DECIMALS IS + .O2 3-8-91G
ON 3 PLACE DECIMALS IS + .OO2 CLEVELAND, OHIO U.S.A. SNUBBER SCHEMATIC
12-20-96F SUBJECT
ON ALL ANGLES IS + .5 OF A DEGREE
SCALE NONE
MATERIAL TOLERANCE ("t") TO AGREE SHT.
WITH PUBLISHED STANDARDS DR. MCW DATE 3-26-90 CHK. SUP’S’D’G. NO. S 19687
G-7
G-8

NOTES
IDEALARC CV-400
G-8

Manual Del Operador - CV400

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RETURN TO MAIN INDEX

Safety Depends on You

Lincoln arc welding and cutting

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CALIFORNIA PROPOSITION 65 WARNINGS

PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

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ELECTRIC SHOCK can kill. ARC RAYS can burn.

form phosgene, a highly toxic gas, and other irritating

5.e. Also see item 1.b.

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cause fire or explosion. if damaged.

area as practical. Work cables connected to the building

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allique ou des grilles metalliques, principalement dans

2. Dans le cas de travail au dessus du niveau du sol, se protéger

contre les chutes dans le cas ou on recoit un choc. Ne jamais

soudage. Se protéger avec des vêtements de protection libres

5. Toujours porter des lunettes de sécurité dans la zone de

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RETURN TO MAIN INDEX

Theory of Operation .............................................................................................................Section E

Parts Manual ...............................................................................................................................P-236

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Reconnect Procedure .................................................................................................................A-6

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TECHNICAL SPECIFICATIONS - IDEALARC CV-400

INPUT - THREE PHASE ONLY

RECOMMENDED INPUT WIRE AND FUSE SIZES

Volts/Hz Nameplate Size (IEC) Sizes AWG (IEC) Sizes

* No added capacity over NEMA rated 36V at 400 amps.

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LOCATION AND VENTILATION ELECTRICAL INPUT CONNECTIONS

• Lift only with equipment of adequate

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GROUND CONNECTION INPUT SUPPLY CONNECTIONS

terminal, marked on the input box floor with the symbol

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FIGURE A.2 INPUT WIRE AND FUSE SIZE

INPUT POWER SUPPLY CONNECTIONS

1. INPUT SUPPLY LINE ENTRY HOLE

Have a qualified electrician connect the input power

3. RECONNECT PANEL/JUMPER LINKS

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RECONNECT PROCEDURE OUTPUT CONNECTIONS

DUAL VOLTAGE MACHINE

CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

4. CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC

THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.

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1. NEGATIVE (-) WELDING CABLE CONNECTION

TABLE A.1 - CABLE SIZES FOR COMBINED LENGTH

(100% DUTY (50% DUTY

50 to 100 ft 3/0 2/0

100 to 150 ft 3/0 3/0

150 to 200 ft 3/0 3/0

200 to 250 ft 4/0 4/0