Lincoln Electric Welder SVM136 A User Manual
RETURN TO MAIN INDEX  
SVM136-A  
November 1997  
®
IDEALARC CV-400  
For Machines with Code Numbers 10084 thru 10087  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be in-  
creased by proper installation . . .  
and thoughtful operation on  
your part. 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.  
SERVICE MANUAL  
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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ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
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  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
IDEALARC CV-400  
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iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
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  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•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  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
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  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
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  
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iv  
iv  
SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
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  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
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  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
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  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
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.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
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  
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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  
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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  
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A-2  
A-2  
INSTALLATION  
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%  
60%  
50%  
400  
450  
500  
36*  
38  
40  
OUTPUT  
Current  
Range  
Voltage  
Range  
Maximum Open  
Circuit Voltage  
Auxiliary  
Power  
60 - 500 Amps  
12 - 42 Volts  
46 VDC  
115 VAC, 10 Amps  
42 VAC, 10 Amps  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
Fuse  
(Super Lag)  
or Breaker  
Size  
Type 75° C  
Copper Wire in  
Conduit AWG  
(IEC) Sizes  
Type 75° C  
Input Voltage/  
Frequency  
Volts/Hz  
Input Amps  
Rating on  
Nameplate  
Copper Ground  
Wire in Conduit  
AWG (IEC) Sizes  
230  
460  
77  
39  
125  
60  
3 (27 mm2)  
6 (13 mm2)  
8 (8.4 mm2)  
10 (5.3 mm2)  
PHYSICAL DIMENSIONS  
2
Height  
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  
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A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
The IDEALARC CV-400 weighs 357 pounds (162 kilo-  
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  
STACKING  
WARNING  
IDEALARC CV-400s may be stacked three high. The  
bottom machine must be on a stable, hard, level sur-  
face capable of supporting the weight of up to three  
machines (1071 pounds/486 kilograms). Be sure that  
the two holes in the top front corners of the bottom  
machine line up with the holes in the base rails of the  
machine above. Fasten the machines together with  
5/16" bolts, lockwashers, and nuts through these holes.  
The lift hook is positioned so that it fits without interfer-  
ence under the base of the second machine.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts such as output terminals or  
internal wiring.  
• Insulate yourself from the work  
and ground.  
• Turn power switch off before connecting or discon-  
necting cables or connections.  
• Always connect grounding terminal to a proper elec-  
trical earth ground.  
TILTING  
Place the machine on a secure, level surface. Any sur-  
faces you place it on other than the ground must be  
firm, non-skid, and structurally sound.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
LOCATION AND VENTILATION  
ELECTRICAL INPUT CONNECTIONS  
Place the IDEALARC CV-400 where clean, cooling air  
can flow freely in through the front louvers and out  
through the rear louvers. Keep dust, dirt, and other for-  
eign materials that can be drawn into the machine to a  
minimum. Failure to observe these precautions can  
lead to excessive operating temperatures and nuisance  
shut-downs.  
Be sure the voltage, phase, and frequency of the input  
power is as specified on the rating plate, located on the  
case front control panel. See Figure A.1.  
Input supply line entry is through a hole in the case rear  
top panel. A removable door covers the input connec-  
tion box, which contains the input contactor (CR1) and  
reconnect panel assembly for multiple voltage connec-  
tion. Input power is connected to the three line termi-  
nals on the input contactor. See Figure A.2.  
THE CV-400 carries an IP-21 environmental rating.  
Locate indoors or shelter from falling water such as rain.  
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  
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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  
grounding lead must be connected to the grounding  
terminal, marked on the input box floor with the symbol  
(See Figure A.2). Refer to Technical Specifi-  
cations page for proper ground wire size.  
Be sure the voltage, phase, and frequency of the input  
power is the same as specified on the rating plate.  
WARNING  
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  
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A-5  
A-5  
INSTALLATION  
FIGURE A.2  
REAR PANEL  
INPUT WIRE AND FUSE SIZE  
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  
cover of the access panel cover. Also refer to  
Reconnect Procedure later in this section.  
1. INPUT SUPPLY LINE  
2. INPUT CONTACTOR  
3. RECONNECT PANEL/JUMPER LINKS  
IDEALARC CV-400  
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A-6  
A-6  
INSTALLATION  
RECONNECT PROCEDURE  
OUTPUT CONNECTIONS  
Multiple input voltage welders are shipped from the fac-  
tory connected for the highest voltage listed on the  
machine's rating plate. Before installing the welder, be  
sure the reconnect panel is connected for the proper  
voltage.  
CONNECT ELECTRODE AND WORK  
LEADS TO OUTPUT TERMINALS  
The output (welding) cables are connected to the out-  
put terminals marked "+" and "-" . These 1/2" terminals  
are located at the lower right and lower left corners of  
the front panel. See Figure A.5.  
Failure to follow these instructions can cause immedi-  
ate failure of components in the welder.  
See Table A.1 for recommended cable sizes for com-  
bined lengths of electrode and work cables.  
To reconnect a multiple voltage machine to a different  
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  
Do not touch electrically live parts  
INPUT SUPPLY CONNECTION DIAGRAM  
removed  
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.  
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS  
Disconnect input power before  
Only qualified persons should install,  
use or service this equipment  
servicing  
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  
LEAST 600 VOLT INSULATION.  
CR1  
W
V
L3  
L2  
LINES  
INPUT  
3. CONNECT L1, L2  
&
L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS  
CONTACTOR  
TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.  
{
U
L1  
4. CONNECT TERMINAL MARKED  
CODES.  
TO GROUND PER LOCAL AND NATIONAL ELECTRIC  
H1  
GND  
H2  
H3  
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.  
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE  
USE. SECURE THE REMAINING HEX NUTS IN PLACE.  
PILOT  
TRANSF.  
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.  
CR1  
W
L3  
L2  
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT  
LEAST 600 VOLT INSULATION.  
LINES  
INPUT  
V
CONTACTOR  
3. CONNECT L1, L2  
&
L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS  
{
U
L1  
TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.  
4. CONNECT TERMINAL MARKED  
CODES.  
TO GROUND PER LOCAL AND NATIONAL ELECTRIC  
H1  
GND  
H3  
H2  
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.  
PILOT  
TRANSF.  
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.  
IDEALARC CV-400  
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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  
CYCLE)  
(50% DUTY  
CYCLE)  
CABLE LENGTHS  
UP TO 50 ft  
(15 m)  
3/0  
2/0  
85 mm2  
67 mm2  
50 to 100 ft  
(15 to 30 m)  
3/0  
2/0  
85 mm2  
67 mm2  
100 to 150 ft  
(30 to 46 m)  
3/0  
3/0  
85 mm2  
85 mm2  
150 to 200 ft  
(46 to 61 m)  
3/0  
3/0  
85 mm2  
85 mm2  
200 to 250 ft  
(67 to 76 m)  
4/0  
4/0  
107 mm2  
107 mm2  
IDEALARC CV-400  
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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  
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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  
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B-2  
B-2  
OPERATION  
OPERATING INSTRUCTIONS  
Read and understand this entire section of operating  
instructions before operating the machine.  
SAFETY INSTRUCTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet 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  
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B-3  
B-3  
OPERATION  
OPERATIONAL FEATURES AND  
CONTROLS  
GENERAL DESCRIPTION  
The IDEALARC CV-400 is an SCR controlled three-  
phase input, DC output power source for welding. It  
uses a single range potentiometer control. The  
welder's unique combination of transformer, three  
phase hybrid rectifier, capacitor bank, output choke,  
and solid state control system deliver outstanding per-  
formance.  
The following operational controls are standard on the  
IDEALARC CV-400:  
• Power Source Pilot Light  
• ON/OFF Power Toggle Switch  
• Output Control Potentiometer  
• Output Control Switch (with Local or Remote posi-  
tions)  
RECOMMENDED PROCESSES  
• Auxiliary Power Connections for Wire Feeder and  
Other Equipment (115V and 42V)  
The IDEALARC CV-400 is a constant voltage power  
source only. It is recommended for all open arc  
processes including Innershield and all solid wire and  
gas procedures within its capacity of 60 to 500 amps.  
• Thermal Protection Indicator Light  
• Voltmeter "+" Electrode or "-" Electrode Switch  
The CV-400 can be connected to wire feeding equip-  
ment, including:  
DESIGN FEATURES  
• Automatic wire feeders NA-3, NA-5, and NA-5R.  
(Requires the CV-400 Diode Kit option to use the cold  
start and cold electrode sensing features of these  
feeders.)  
• Input line voltage compensation keeps output con-  
stant for fluctuations of ±10%.  
• 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  
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B-4  
B-4  
OPERATION  
WELDING CAPABILITY  
LIMITATIONS  
The CV-400 has the following duty cycle ratings. If the  
duty cycle is exceeded, a thermal protector will shut off  
the machine output until it cools to normal operating  
temperature. The amber thermal protection indicator  
light will turn on until the machine cools.  
The IDEALARC CV-400 has no provisions for parallel-  
ing. It should not be used outdoors without rain shel-  
tering.  
Duty Cycle*  
100%  
Amps  
400  
Volts  
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  
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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
2
7
6
5
4
3
1. POWER SOURCE PILOT LIGHT  
2. ON/OFF POWER TOGGLE SWITCH  
3. OUTPUT CONTROL POTENTIOMETER  
4. OUTPUT CONTROL SWITCH (WITH LOCAL OR  
REMOTE POSITIONS)  
6. DC AMMETER  
7. AUXILIARY POWER CONNECTIONS FOR WIRE FEEDER AND  
OTHER EQUIPMENT (115V AND 42V)  
8. VOLTMETER "+" ELECTRODE OR "-" ELECTRODE SWITCH  
9. THERMAL PROTECTION INDICATOR LIGHT  
5. DC VOLTMETER  
1. POWER SOURCE PILOT LIGHT: This light indi-  
cates that the power source input contactor is ener-  
gized (closed). This also means that the main power  
transformer and all auxiliary control transformers are  
energized.  
7. AUXILIARY POWER AND REMOTE CONTROL  
CONNECTIONS FOR WIRE FEEDER AND OTHER  
EQUIPMENT (115V AND 42V): The 14-pin amphe-  
nol receptacle provides either 115 or 42 VAC as well  
as remote control connections. Terminal strips with  
screw connections are located behind the hinged  
control panel for hard wired control. A strain relief  
connector is provided for cable entry. The 42 VAC  
auxiliary is not available at the terminal strip.  
2. ON/OFF POWER TOGGLE SWITCH: Energizes or  
deengergizes the input contactor. The switch turns  
the machine ON or OFF. Position "I" is ON; position  
"0" is OFF.  
8. VOLTMETER "+" ELECTRODE OR "-" ELEC-  
TRODE SWITCH: Selects the electrode polarity for  
the remote work sensing lead (#21) when using  
automatic or semiautomatic wire feeders. It must  
agree with the actual electrode polarity chosen and  
with the wire feeder polarity switch on the feeder.  
3. OUTPUT CONTROL POTENTIOMETER: Controls  
output voltage.  
4. OUTPUT CONTROL SWITCH (WITH LOCAL OR  
REMOTE POSITIONS): Selects the mode of control.  
In the "Local" position, control is by the machine con-  
trol panel. In the "Remote" position, control is by  
either a wire feeder unit or through an optional  
remote control device.  
9. THERMAL PROTECTON INDICATOR LIGHT: This  
light indicates that either of the two protective ther-  
mostats has opened. Welding output is disabled but  
input power is still applied.  
5. DC VOLTMETER (OPTIONAL): Displays actual out-  
put voltage.  
10. 42 VAC AUXILIARY CIRCUIT BREAKER: This 10  
amp breaker protects the 42 VAC auxiliary circuit.  
6. DC AMMETER (OPTIONAL): Displays actual output  
current.  
11. 115VAC AUXILIARY CIRCUIT BREAKER: This 10  
amp breaker protects the 115 VAC auxiliary circuit.  
IDEALARC CV-400  
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B-6  
B-6  
OPERATION  
3. Set the OUTPUT CONTROL switch to "Local."  
(Exception: when using an LN-9, LN-9 GMA, or NA-  
5 wire feeder, set the switch to "Remote." Otherwise,  
the wire feeder may automatically shut down.)  
WELDING OPERATION  
LOCAL CONTROL  
The following procedures are for using the CV-400 in  
the local control mode of operation. For remote control  
of the machine, see the Remote Control section.  
4. Set the ON/OFF switch to the ON position (I). The  
power source pilot light glows and the fan starts.  
5. Set the OUTPUT CONTROL Potentiometer to the  
desired voltage.  
Before operating the machine, make sure you have all  
materials needed to complete the job. Be sure you are  
familiar with and have taken all possible safety precau-  
tions before starting work. It is important that you follow  
these operating steps each time you use the machine.  
6. Make the weld.  
1. Turn on the main AC input power to the machine.  
REMOTE CONTROL  
2. Set the VOLTMETER "+" or "-" switch to the appro-  
priate position.  
The toggle switch on the control panel labeled "Output  
Control Remote" gives you the option of controlling the  
machine output from a remote location. In the  
"Remote" position a wire feeder with remote control  
capabilities or a remote control device such as a K775  
must be connected to the CV-400. See the  
Accessories section for wire feeder installation infor-  
mation.  
- Set toggle to " Electrode Negative" position if the  
electrode is connected to the negative (-) output ter-  
minal.  
- Set toggle to "Electrode Positive" position if the elec-  
trode is connected to the positive (+) output terminal.  
IDEALARC CV-400  
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B-7  
B-7  
OPERATION  
OVERLOAD PROTECTION  
AUXILIARY POWER  
The power source is thermostatically protected with  
proximity thermostats against overload or insufficient  
cooling. One thermostat is located on the nose of the  
center bottom primary coil and a second thermostat is  
attached to the lead connecting the secondaries. Both  
thermostats are connected in series with 2-4 circuit. If  
the machine is overloaded, the primary thermostat will  
open, the output will be zero, the amber thermal pro-  
tection light will be on and the fan will continue to run.  
The secondary thermostat will open either with an  
excessive overload or insufficient cooling. The output  
will be zero, the amber protection light will be on and  
the fan will continue to run. When the thermostats  
reset, the protection light will be off.  
On machines above code 9400, the IDEALARC CV-  
400 can provide nominally 115 volts AC and 42 volts  
AC auxiliary power for operating wire feeding equip-  
ment and other accessories. This power is available at  
the 14-pin amphenol on the control panel and/or at the  
terminal strip behind the hinged control panel on the  
case front. On the amphenol, 115 volts AC is available  
at pins A and J (Domestic and Export models only); 42  
volts AC is available at pins I and K. On the terminal  
strip, 115 volts AC is available at terminals 31 and 32;  
42 volts AC is not available at the terminal strip. The  
two circuits, 115 volts AC and 42 volts AC, are isolated;  
and each is protected by a 10 amp circuit breaker.  
The power source is also protected against overloads  
on the SCR bridge assembly through the solid state  
fault protection circuit. This circuit senses an overload  
on the power source and limits the output to approxi-  
mately 550 amps by phasing back the SCR’s.  
FRONT VIEW OF 14-PIN CONNECTOR  
RECEPTACLE  
K=42  
A=32  
J=31  
Protection is provided to protect the circuitry from acci-  
dental grounds. If leads 75, 76, or 77 are accidentally  
“grounded” to the positive output lead, the output will be  
reduced to a low value, thus preventing any damage to  
the machine. If the ground occurs between 75, 76, 77  
and the negative output lead, one of the PC board elec-  
tronic “self-restoring” fuses will blow, preventing any  
machine damage. After the ground is cleared, the  
fuses automatically reset within a few seconds.  
B=GND  
L
I=41  
N
C=2  
H=21  
D=4  
G=75  
E=77  
F=76  
M
PIN  
LEAD NO.  
FUNCTION  
A
B
C
D
E
F
G
H
I
32  
GND  
2
115 VAC  
Chassis Connection  
Trigger Circuit  
Trigger Circuit  
Output Control  
Output Control  
Output Control  
Work Connection  
42 VAC  
4
77  
76  
75  
21  
41  
31  
42  
---  
J
K
L
115 VAC  
42 VAC  
---  
M
N
---  
---  
---  
---  
IDEALARC CV-400  
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B-8  
B-8  
NOTES  
IDEALARC CV-400  
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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  
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C-2  
C-2  
ACCESSORIES  
The K775 consists of a control box with 28 ft (8.5m) of  
four conductor cable. This connects to terminals 75,  
76, and 77 on the terminal strip and the case ground-  
OPTIONS/ACCESSORIES  
The following options/accessories are available for your  
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  
on the front. These devices will give the same control  
as the output control on the machine.  
FACTORY INSTALLED OPTIONS  
Diode Option - This internally installed option allows  
use of the cold start and cold electrode sensing fea-  
tures of the NA-3, NA-5, or NA-5R automatic wire feed-  
ers. See the topic Connecting the NA-3 [NA-5] to the  
CV-400.  
Remote Control Adapter Cable (K864) - A "V" cable  
12 inches (.30 m) long to connect a K857 Remote  
Control with a wire-feeder control cable (14-pin con-  
nector) and the machine (14-pin connector). If a remote  
control is used alone, the wire-feeder connection is not  
used. See Figure C.1.  
Ammeter and Voltmeter - Display output current and  
voltage when welding.  
Capacitor Discharge Circuit (K828-1) - Mounts inside  
the CV-400. Recommended when:  
FIELD INSTALLED OPTIONS  
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.  
Eliminates possible arc flash re-start of weld when  
trigger interlock is used. Not required with current LN-  
8 (above Code 8700), or LN-9s with serial numbers  
above 115187 (manufactured after 12/83), or any LN-  
9 having an L6043-1 Power PC Board.  
Undercarriage (K817P) - Includes a platform and  
polyolefin wheels for easily moving the welder.  
Undercarriage (K841) - Includes a platform, wheels,  
and brackets for supporting the welder and two gas  
cylinders.  
• CV-400 is used with an LN-22 equipped with an older  
K279 Contactor-Voltage Control Option. Eliminates  
electrode overrun when gun trigger is released. Not  
required when later K279 (above Code 8800) is used.  
Remote Output Control (K775 or K857 with K864  
Adapter Plug) - The K857 has a 6-pin MS-style con-  
nector. The K857 requires a K864 adapter cable which  
connects to the 14-pin connector on the CV-400.  
• A small spark is objectionable if electrode touches  
work just after the trigger is released.  
FIGURE C.1  
REMOTE CONTROL ADAPTER CABLE (K864)  
CABLE RECEPTACLE (6 SOCKET)  
TO K857 REMOTE CONTROL  
STRAIGHT PLUG (14 PIN)  
TO POWER SOURCE  
CABLE RECEPTACLE (14 SOCKET)  
TO: L-7 WIRE FEEDER  
IDEALARC CV-400  
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C-3  
C-3  
ACCESSORIES  
CONNECTION OF LINCOLN ELECTRIC AUTOMATIC OR SEMIAUTOMATIC  
WIRE FEEDERS  
NOTE: When using a CV-400 with wire feeders, there  
may be a small spark if the electrode contacts the work  
or ground within a few seconds after releasing the trig-  
WARNING  
ELECTRIC SHOCK can kill.  
ger. With some wire feeders, when the electrical inter-  
lock is in the ON position the arc can restart if the elec-  
trode touches the work or ground during these few sec-  
onds. Refer to K828-1 capacitor discharge circuit ear-  
lier in this section.  
• Only qualified personnel should per-  
form this maintenance.  
• Turn the input power OFF at the dis-  
connect switch or fuse box before  
working on this equipment.  
The following descriptions show how to connect the  
wire feeders using the terminal strip.  
• Do not touch electrically hot parts.  
• Insulate yourself from work and ground.  
• Always wear dry insulating gloves.  
AUTOMATIC WIRE FEEDERS  
CONNECTING THE NA-3 TO THE  
IDEALARC CV-400  
Auxiliary power for wire feeder operation is available at  
both a 14-pin amphenol and at terminal strips with  
screw-type connections located behind the hinged con-  
trol panel on the front of the machine. The 14-pin  
amphenol can provide both 115 VAC (pins A and J) and  
42 VAC (pins I and K). The terminal strip provides only  
115 VAC (terminals 31 and 32). The two circuits are iso-  
lated, and each is protected by a 10A circuit breaker.  
1. Set the CV-400 POWER toggle switch to the OFF (0)  
position.  
2. Disconnect main AC input power to the CV-400.  
3. Connect the wire feeder control cable leads to the  
CV-400 terminal strip as shown in Figure C.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  
STRIPS  
CONTROL  
CABLE  
TO  
21  
AUTOMATIC  
CONTROL  
BOX  
4
GND  
21  
4
2
BLANK  
31  
2
32  
31  
32  
75  
76  
77  
75  
76  
77  
-
+
NEGATIVE  
POSITIVE  
ELECTRODE  
CABLE TO  
AUTOMATIC  
EQUIPMENT  
TO  
WORK  
IDEALARC CV-400  
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C-4  
C-4  
ACCESSORIES  
5. Extend wire feeder control cable lead #21 so it can  
be connected directly to the work piece.  
CONNECTING THE NA-5 TO THE  
IDEALARC CV-400  
a. Make a bolted connection using AWG #14 or larg-  
er insulated wire. Tape the bolted connection with  
insulating tape.  
1. Set the CV-400 POWER toggle switch to the OFF (0)  
position.  
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  
CABLE  
TERMINAL  
STRIPS  
TO  
21  
4
AUTOMATIC  
CONTROL  
BOX  
GND  
21  
4
2
BLANK  
31  
32  
2
31  
32  
75  
76  
77  
75  
76  
77  
-
+
NEGATIVE  
POSITIVE  
ELECTRODE  
CABLE TO  
AUTOMATIC  
EQUIPMENT  
TO  
WORK  
IDEALARC CV-400  
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C-5  
C-5  
ACCESSORIES  
5. Extend wire feeder control cable lead #21 so it can  
be connected directly to the work piece.  
NOTE: The connection diagram shown in Figure C.3  
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  
insulating tape.  
a. Set the CV-400 POWER toggle switch to the OFF (0)  
position.  
b. An S-16586- X remote voltage sensing work lead  
is available for this purpose.  
b. Move the electrode cable to the negative (-) output  
terminal.  
c. Keep the #21 lead electrically separate from the  
work cable circuit and connection.  
c. Move the work cable to the positive (+) output termi-  
nal.  
d. Tape the #21 lead to the work cable for ease of  
use.  
d. Set the VOLTMETER toggle switch to negative (-).  
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  
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C-6  
C-6  
ACCESSORIES  
a. Make a bolted connection using AWG #14 or larg-  
er insulated wire. Tape the bolted connection with  
insulating tape.  
SEMIAUTOMATIC WIRE FEEDERS  
CONNECTING THE LN-7 TO THE  
IDEALARC CV-400 (TERMINAL STRIP)  
b. An S-16586- X remote voltage sensing work lead  
is available for this purpose.  
1. Set the CV-400 POWER toggle switch to the OFF (0)  
position.  
c. Keep the #21 lead electrically separate from the  
work cable circuit and connection.  
2. Disconnect main AC input power to the CV-400.  
d. Tape the #21 lead to the work cable for ease of  
use.  
3. Connect the wire feeder control cable leads to the  
CV-400 terminal strip as shown in Figure C.4.  
6. Set voltmeter toggle switch to match electrode polar-  
ity.  
4. Connect the wire feeder control cable ground lead to  
the frame terminal marked  
.
NOTE: The connection diagram shown in Figure C-  
4 shows the electrode connected for positive polari-  
ty. To change polarity:  
NOTE: The CV-400 must be properly grounded.  
5. PERFORM THIS STEP ONLY IF THE LN-7 IS  
EQUIPPED WITH A METER KIT.  
a. Set the CV-400 POWER toggle switch to the OFF  
(0) position  
NOTE: If the work cable length is less than 25 feet  
and the connections to the work piece are secure,  
then wire feeder control cable lead #21 can be con-  
nected directly to the CV-400 terminal strip.  
b. Move the electrode cable to the negative (-) output  
terminal.  
c. Move the work cable to the positive (+) output ter-  
minal.  
Extend wire feeder control cable lead #21 so it can  
be connected directly to the work piece.  
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  
STRIPS  
CONTROL  
CABLE  
TO  
21  
LINE-7  
INPUT  
CABLE  
PLUG  
4
GND  
21  
4
2
BLANK  
31  
2
32  
31  
32  
75  
76  
77  
75  
76  
77  
-
+
NEGATIVE  
POSITIVE  
ELECTRODE  
CABLE TO  
AUTOMATIC  
EQUIPMENT  
TO  
WORK  
IDEALARC CV-400  
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C-7  
C-7  
ACCESSORIES  
NOTE: Using the extended #21 lead eliminates the  
need to use the LN-9's remote work lead accesso-  
ry, which has a direct work lead jack.  
CONNECTING THE LN-8 OR LN-9 TO THE  
IDEALARC CV-400  
1. Set the CV-400 POWER toggle switch to the OFF (0)  
position.  
6. Connect the LN-9 wire feeder control jumpers on  
the Voltage Control board. See LN-9 operator's  
manual.  
2. Disconnect main AC input power to the CV-400.  
3. Connect the wire feeder control cable leads to the  
CV-400 terminal strip as shown in Figure C.5.  
NOTE: The connection diagram shown in Figure C.5  
shows the electrode connected for positive polarity.  
To change polarity:  
4. Connect the wire feeder control cable ground lead  
to the frame terminal marked  
.
a. Set the CV-400 POWER toggle switch to the OFF  
(0) position.  
5. Extend wire feeder control cable lead #21 so it can  
be connected directly to the work piece.  
b. Move the electrode cable to the negative (-) out-  
put terminal.  
a. Make a bolted connection using AWG #14 or  
larger insulated wire. Tape the bolted connection  
with insulating tape.  
c. Move the work cable to the positive (+) output  
terminal.  
b. An S-16586- X remote voltage sensing work lead  
is available for this purpose.  
d. Set the VOLTMETER toggle switch on power  
source to negative (-).  
c. Keep the #21 lead electrically separate from the  
work cable circuit and connection.  
e. Set the voltmeter toggle switch on feeder (if  
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  
TERMINAL  
STRIPS  
WIRE FEEDER  
CONTROL CABLE  
TO  
INPUT  
CABLE  
21  
4
GND  
21  
4
2
BLANK  
31  
2
32  
31  
32  
75  
76  
77  
75  
76  
77  
-
+
NEGATIVE  
POSITIVE  
ELECTRODE  
CABLE TO  
AUTOMATIC  
EQUIPMENT  
TO  
WORK  
IDEALARC CV-400  
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C-8  
C-8  
NOTES  
IDEALARC CV-400  
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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  
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D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ROUTINE AND PERIODIC  
MAINTENANCE  
WARNING  
To avoid receiving an electric shock, keep electrode  
holders and cable insulation in good condition.  
ELECTRIC SHOCK can kill.  
• Only qualified personnel should perform  
this maintenance.  
1. Disconnect power supply lines to the machine before  
performing periodic maintenance.  
• Turn the input power OFF at the discon-  
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  
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.  
• Do not touch electrically hot parts.  
• 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  
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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
5
1
2
4
3
IDEALARC CV-400  
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D-4  
D-4  
NOTES  
IDEALARC CV-400  
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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  
NEGATIVE  
OUTPUT  
TERMINAL  
CONTROL BOARD  
F
G
A
T
S
I
E
E
D
B
A
C
K
POWER  
SWITCH  
G
N
A
E
MAIN  
TRANSFORMER  
L
S
R
F
E
E
D
B
A
C
K
E
C
O
N
N
E
C
T
OUTPUT  
CAPACITORS  
POSITIVE  
OUTPUT  
TERMINAL  
SHUNT  
INPUT  
CONTACTOR  
SCR / DIODE  
HYBRID BRIDGE  
T
E
R
M
I
N
A
L
115VAC  
42VAC  
REMOTE  
CONTROL  
S
T
R
I
P
s
TO  
CONTROL  
BOARD  
FAN  
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  
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E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – INPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER  
OUTPUT  
CONTROL  
CONTROL  
TRANSFORMER  
NEGATIVE  
OUTPUT  
TERMINAL  
CONTROL BOARD  
F
G
A
T
S
I
E
E
D
B
A
C
K
POWER  
SWITCH  
G
N
A
E
MAIN  
TRANSFORMER  
L
S
R
F
E
E
D
B
A
C
K
E
C
O
N
N
E
C
T
OUTPUT  
CAPACITORS  
POSITIVE  
OUTPUT  
TERMINAL  
SHUNT  
INPUT  
CONTACTOR  
SCR / DIODE  
HYBRID BRIDGE  
T
E
R
M
I
N
A
L
115VAC  
42VAC  
REMOTE  
CONTROL  
S
T
R
I
P
s
TO  
CONTROL  
BOARD  
FAN  
14 PIN AMPHENOL  
INPUT LINE VOLTAGE, CONTACTOR  
AND MAIN TRANSFORMER  
The desired three-phase input power is connected to  
the CV-400 through an input contactor, located in the  
input box at the rear of the machine. Two phases of the  
input line are also connected to the control transformer,  
which, through the power switch, supplies power to  
activate the input contactor.  
The finishes or "neutrals" of the main secondary coils  
are connected together, and the three starts of the sec-  
ondary windings are connected to the rectifier bridge  
assembly. In addition, the main transformer has sepa-  
rate and isolated 115VAC and 42VAC auxiliary wind-  
ings. The 115VAC is available at the terminal strip and  
the 14 pin amphenol and is protected by a 10 amp cir-  
cuit breaker. The 42VAC is available at the 14 pin  
amphenol only and is also protected by a 10 amp cir-  
cuit breaker. The three 21VAC phase angle windings  
are also housed in the main transformer assembly.  
These windings provide power and "timing" for the con-  
trol board.  
A reconnect panel allows the user to configure the  
machine for the desired input voltage. This AC voltage  
is applied to the primary of the main transformer.  
The transformer changes the high voltage, low current  
input power to a lower voltage, higher current output.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
IDEALARC CV-400  
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E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – OUTPUT CONTROL, RECTIFICATION AND FEEDBACK  
OUTPUT  
CONTROL  
CONTROL  
TRANSFORMER  
NEGATIVE  
OUTPUT  
TERMINAL  
CONTROL BOARD  
F
G
A
T
S
I
E
E
D
B
A
C
K
POWER  
SWITCH  
G
N
A
E
MAIN  
TRANSFORMER  
L
S
R
F
E
E
D
B
A
C
K
E
C
O
N
N
E
C
T
OUTPUT  
CAPACITORS  
POSITIVE  
OUTPUT  
TERMINAL  
SHUNT  
INPUT  
CONTACTOR  
SCR / DIODE  
HYBRID BRIDGE  
T
E
R
M
I
N
A
L
115VAC  
42VAC  
REMOTE  
CONTROL  
S
T
R
I
P
s
TO  
CONTROL  
BOARD  
FAN  
14 PIN AMPHENOL  
OUTPUT CONTROL,  
RECTIFICATION AND FEEDBACK  
A "dry closure" of leads #2 and #4, either at the termi-  
nal strip or the 14 pin amphenol, signals the control  
board to apply gate firing signals to the SCR/diode  
bridge, which creates a DC voltage at the output of  
the bridge assembly. This output is filtered by the  
capacitors to reduce the ripple content of the wave-  
form. Thus, a smoother DC output is created. The  
choke, which is in series with the negative output ter-  
minal, stores energy and provides current filtering.  
The three-phase AC output from the main transformer  
secondary is rectified and controlled through the  
SCR/diode bridge. Output current and voltage is  
sensed at the shunt and output capacitors, respective-  
ly. This feedback information is processed in the con-  
trol board. The control board compares the commands  
of the output control (or remote control) with the feed-  
back information and sends the appropriate gate firing  
signals to the SCR/diode bridge. See SCR Operation  
in this section.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
IDEALARC CV-400  
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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  
#4  
#2  
CIRCUIT  
BREAKER  
SECONDARY  
THERMOSTAT  
PRIMARY  
THERMOSTAT  
#240  
#41  
#41  
CONTROL BOARD  
PROTECTIVE DEVICES AND  
CIRCUITS  
Two thermostats protect the CV-400 from excessive  
operating temperatures and overload conditions.  
Excess operating temperatures may be caused by  
insufficient cooling air or by operating the machine  
beyond the duty cycle and output rating. The primary  
thermostat is located on the nose of the center bottom  
primary coil. The secondary thermostat is attached to  
the lead connecting the secondaries. Both thermostats  
are connected in series with the trigger circuits. If the  
machine is over-heated, the thermostats will open and  
output will be zero. The thermal protection light will  
glow and the fan will continue to run. See Figure E.4,  
CV-400 Trigger And Thermal Light Circuit. Under nor-  
mal conditions the Thermal Light is "shorted out" by  
the circuit breaker and thermostat circuit. If the ther-  
mostats or the circuit breaker opens, more current will  
flow through the Thermal Light circuit, and the light will  
glow.  
The power source is also protected against overloads  
on the SCR bridge assembly through the solid state  
fault protection circuit. This circuit senses an overload  
on the power source and limits the output to approxi-  
mately 550 amps by phasing back the SCRs.  
Protection is also provided to protect the circuitry from  
accidental grounds. If the customer accidentally  
"grounds" 75, 76, or 77 to the positive output lead, the  
CV-400 output will be reduced to a very low value, thus  
preventing any damage to the machine. If the ground  
occurs between 75, 76, and 77 and the negative output  
lead, one of the PC board electronic "self-restoring"  
fuses will blow, preventing any machine damage. After  
the ground is cleared, the fuses automatically reset  
within a few seconds.  
IDEALARC CV-400  
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E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – SCR OPERATION  
INPUT  
CATHODE  
OUTPUT  
GATE  
ANODE  
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  
device used to control rather large currents to a load.  
An SCR acts very much like a switch. When a gate sig-  
nal is applied to the SCR, it is turned ON, and there is  
current flow from anode to cathode. In the ON state the  
SCR acts like a closed switch. When the SCR is turned  
OFF, there is no current flow from anode to cathode;  
thus the device acts like an open switch. As the name  
suggests, the SCR is a rectifier, so it passes current  
only during positive half cycles of the AC supply. The  
positive half cycle is the portion of the sine wave in  
which the anode of the SCR is more positive than the  
cathode.  
An SCR is fired by a short burst current into the gate.  
This gate pulse must be more positive than the cathode  
voltage. Since there is a standard PN junction between  
gate and cathode, the voltage between these terminals  
must be slightly greater than 0.6V. Once the SCR has  
fired, it is not necessary to continue the flow of gate  
current. As long as current continues to flow from  
anode to cathode the SCR will remain on. When the  
anode to cathode current drops below a minimum  
value called holding current, the SCR will shut off. This  
normally occurs as the AC supply voltage passes  
through zero into the negative portion of the sine wave.  
If the SCR is turned on early in the positive half cycle,  
the conduction time is longer, resulting in greater SCR  
output. If the gate firing occurs later in the cycle, the  
conduction time is less, resulting in lower SCR output.  
When an AC supply voltage is applied to the SCR, the  
device spends a certain portion of the AC cycle time in  
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  
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E-6  
E-6  
NOTES  
IDEALARC CV-400  
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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  
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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  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure list-  
ed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
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  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM” (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into two main categories: Output Problems and  
Welding Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this section.  
Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the order  
listed. In general, these tests can be conducted  
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  
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F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
WARNING  
• Remove the PC Board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC Board on or near paper, plastic or cloth which  
could have a static charge. If the PC Board can’t be  
installed immediately, put it back in the static-shielding  
bag.  
ELECTRIC SHOCK can kill.  
Have an electrician install and service  
this equipment. Turn the machine OFF  
before working on equipment. Do not  
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  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
• If you return a PC Board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow prop-  
er failure analysis.  
4. Test the machine to determine if the failure symp-  
tom has been corrected by the replacement PC  
board.  
1. Determine to the best of your technical ability that  
the PC board is the most likely component causing  
the failure symptom.  
NOTE: Allow the machine to heat up so that all electri-  
cal components can reach their operating temperature.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and substitute  
it with the original PC board to recreate the original  
problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static elec-  
trical damage and electrical shock. Read the warn-  
ing inside the static resistant bag and perform the  
following procedures:  
a. If the original problem does not reappear  
by substituting the original board, then the  
PC board was not the problem. Continue  
to look for bad connections in the control  
wiring harness, junction blocks, and termi-  
nal strips.  
PC Board can be damaged by  
static electricity.  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the  
machine.  
• Remove your body’s static charge  
before opening the static-shielding  
bag. Wear an anti-static wrist  
strap. For safety, use a 1 Meg  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
ohm resistive cord connected to a  
grounded part of the equipment  
frame.  
6. Always indicate that this procedure was followed  
when warranty reports are to be submitted.  
• If you don’t have a wrist strap,  
touch an unpainted, grounded,  
part of the equipment frame.  
Keep touching the frame to pre-  
vent static build-up. Be sure not to  
touch any electrically live parts at  
the same time.  
Workstations  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Reusable  
Container  
Do Not Destroy  
• Tools which come in contact with the PC Board must  
be either conductive, anti-static or static-dissipative.  
IDEALARC CV-400  
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F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
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  
cover(s) are removed.  
Lincoln Electric Field Service  
Facility for technical assistance.  
Service Department, (216) 383-  
2531 or 1-800-833-9353 (WELD).  
Machine is dead - no output - no  
fan - no pilot light.  
1. Make sure the input power 1. Check the input power switch  
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  
plate and the reconnect panel.  
the power switch (S1) and the  
control transformer (T2) for  
loose or faulty connections. See  
the Wiring Diagram.  
3. Check for blown or missing  
fuses in the input lines.  
3. Perform the Control  
Transformer Test.  
1. Check the three-phase input  
The machine is dead - no output -  
no fan - the pilot light is on.  
voltage at the machine. Input 1. Perform the Input Contactor  
voltage must match the rating  
plate and the reconnect panel.  
Test.  
2. Check the associated leads for  
loose or faulty connections  
between the input contactor  
(CR1), the reconnect panel and  
the main transformer. See the  
Wiring Diagram.  
2. Check for blown or missing  
fuses in the input lines.  
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  
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F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
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  
the machine has no welding output.  
light is on, the primary or sec-  
ondary thermostat is open.  
Allow machine to cool.  
Test.  
2. Perform the SCR/Diode Recti-  
fier Bridge Test.  
2. Make certain the output trigger  
circuit (#2 and #4) is being acti-  
vated by a “closure.”  
3. The control board may be faulty.  
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  
machine rating plate and the  
reconnect panel.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
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) to the “Machine or Local”  
position and control the weld  
output with the machine Output  
Control (R4). If the problem is  
solved, check the remote con-  
(S2) and associated wiring. See  
the Wiring Diagram.  
2. Check feedback leads #220,  
#204, #205 and #206 for loose  
or faulty connections.  
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  
welding output. If leads #75,  
#76 or #77 are “grounded” to the  
negative welding output, the  
machine output may go very  
high without control.  
faulty. Replace.  
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  
(S2) to the “Machine or Local”  
position and control the weld  
output with the machine Output  
Control (R4). If the problem is  
solved, check the remote con-  
and associated wiring. See the  
Wiring Diagram.  
2. Check the Output Control switch  
(S2) and associated wiring. See  
the Wiring Diagram.  
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  
grounded to the positive welding  
output.  
ier Bridge Test.  
5. The control board may be faulty.  
3. Make certain the three-phase  
input voltage is correct and  
matches the machine rating and  
the reconnect panel.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
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  
applied to the machine.  
Normal resistance is 10,000  
ohms. Also check associated  
wiring for loose or faulty connec-  
tions. See the Wiring Diagram.  
2. If remote control is being used,  
set the Output Control switch  
(S2) to the “Machine or Local” 2. Check the Output Control switch  
position and control the weld  
output with the machine Output  
Control (R4). If the problem is  
solved, check the remote control  
unit or wire feeder and associat-  
ed control cable.  
(S2) and associated wiring. See  
the Wiring Diagram.  
3. Perform the Main Transformer  
Test.  
4. Perform the SCR/Diode Bridge  
Rectifier Test.  
5. The control board may be faulty.  
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  
position.  
lines are connected correctly to  
the CV-400.  
(S1) and associated leads. See  
the Wiring Diagram.  
2. Perform the Input Contactor  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
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  
amphenol or the terminal strip.  
If the problem disappears, the  
fault is in the control cable or  
wire feeder.  
between leads #2 and #4. See  
the Wiring Diagram.  
2. Remove plug J3 (SCR gate  
leads) from the control board. If  
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  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
Poor arc characteristics.  
1. Make sure the correct weld pro- 1. Check the output capacitors and  
cedures are being used.  
(Electrode, Gas, etc.)  
connections. A capacitor failure  
is indicated if the small vent plug  
on top of a capacitor is raised or  
blown out.  
2. Check the welding cables for  
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.  
2. The control board may be faulty.  
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.)  
2. Check the welding cables for  
loose or faulty connections.  
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  
voltage and all three phases are  
being applied to the machine.  
fier Bridge Test.  
2. Perform the Main Transformer  
Test.  
2. Make sure the welding process  
is correct for the machine set-  
tings.  
3. The control board may be faulty.  
Replace.  
3. Check the welding cables for  
loose or faulty connections.  
Also make sure cables are sized  
correctly for the welding current.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
TROUBLESHOOTING & REPAIR  
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  
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F-11  
F-11  
TROUBLESHOOTING & REPAIR  
CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued)  
FIGURE F.1 – CONTROL TRANSFORMER AND LEAD LOCATIONS  
5. Locate control transformer leads X1 (top)  
and X2.  
TEST PROCEDURE  
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  
of the contactor. See Figure F.1.  
2. With the 5/16” nut driver, remove the top,  
case sides, and rear input panel.  
b. Lead X2 is spliced into lead #231. See  
the Wiring Diagram. Lead #231 is con-  
nected to the power switch (S1). See  
Figure F.2.  
3. Locate the control transformer (T2) on the  
left side of the input box (facing the back of  
the machine). See Figure F.1.  
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  
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F-12  
F-12  
TROUBLESHOOTING & REPAIR  
CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued)  
FIGURE F.2 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS  
MACHINE FRONT  
BACK OF  
CONTROL  
PANEL  
LEAD #231  
CONNECTION  
METER  
PROBE  
RIGHT SIDE VIEW  
6. Test for 115VAC between leads X1 and  
#231.  
7. Read the meter for 115VAC.  
a. If 115VAC is present, the control trans-  
former is functioning properly.  
NOTE: If the main AC input supply voltage  
varies, the control transformer voltage will  
vary by the same percentage.  
b. If 115VAC is NOT present, go to Step 8.  
8. If 115VAC is not present between leads X1  
and #231, check the spliced connection  
between #231 and X2. Test for correct main  
input supply power to the control transformer  
primary windings (H1, H2, H3, etc.). Check  
the main input supply power hookup to the  
machine. See the Wiring Diagram.  
a. Connect one end of an insulated alligator  
clip to the X1 connection at the input con-  
tactor (CR1) coil. See Figure F.2.  
b. Connect the other end of the alligator clip  
to one of the meter probes. Be sure that  
neither the alligator clip nor the meter  
probe touches any metal surfaces.  
a. If the correct main input supply power to  
the control transformer primary windings  
is present AND the secondary voltage is  
not correct, the control transformer may  
be faulty. Replace.  
c. Connect the other meter probe to the  
#231 connection (top lead) at the power  
switch. See Figure F.2.  
d. Apply input power to the CV-400.  
IDEALARC CV-400  
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F-13  
F-13  
TROUBLESHOOTING & REPAIR  
INPUT CONTACTOR 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 elec-  
trical 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 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  
Volt/ohmmeter (Multimeter)  
5/16” Nut driver  
IDEALARC CV-400 wiring diagrams (See the Electrical Diagrams section of this manual.)  
External 120VAC supply  
IDEALARC CV-400  
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F-14  
F-14  
TROUBLESHOOTING & REPAIR  
INPUT CONTACTOR TEST (continued)  
FIGURE F.3 – INPUT CONTACTOR CONNECTIONS  
X1, #232  
#233  
5. Apply the correct voltage to the machine and  
turn the power switch (S1) ON.  
TEST PROCEDURE  
1. Disconnect the main input supply power to  
the machine.  
6. Check for 120VAC at the contactor coil leads.  
If the 120VAC is NOT present, with the power  
switch (S1) on, check the power switch (S1)  
and associated circuitry. See the Wiring  
2. With the 5/16” nut driver, remove the case  
top and the reconnect panel cover.  
3. Locate the two leads connected to the input  
contactor coil, #233 and X1 #232 (top). See  
Figure F.3 for location.  
Diagram.  
Also perform the Control  
Transformer (T2) Voltage Test.  
If the 120VAC is present and the contactor  
does NOT activate, then the input contactor is  
faulty. Replace the input contactor.  
4. Connect an AC voltmeter to the leads.  
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  
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F-15  
F-15  
TROUBLESHOOTING & REPAIR  
INPUT CONTACTOR TEST (continued)  
FIGURE F.4 – INPUT CONTACTOR TEST CONNECTIONS  
APPLY EXTERNAL  
120 VAC HERE  
(X1, #232 AND #233  
LEAD TERMINALS)  
X1, #232  
#233  
4. With the contactor activated, check the continuity  
across the contacts. (Zero ohms or very low resis-  
tance is normal.) See Figure F.4. If the resistance  
is high, the input contactor is faulty. Replace the  
input contactor.  
TEST FOR CONTACT CONTINUITY  
1. Disconnect the main input supply power to the  
machine.  
2. Remove the two leads connected to the input con-  
tactor coil, #233 and X1/#232. See Figure F.4 for  
location.  
5. When the contactor is NOT activated, the resistance  
should be infinite or very high across the contacts.  
If the resistance is low, the input contactor is faulty.  
Replace the input contactor.  
3. Using the external 120VAC supply, apply 120VAC to  
the terminals of the input contactor coil. If the con-  
tactor does NOT activate, the input contactor is  
faulty. Replace the input contactor.  
IDEALARC CV-400  
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F-16  
F-16  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER (T1) 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 elec-  
trical 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 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  
Volt/ohmmeter (Multimeter)  
5/16” Nut driver  
IDEALARC CV-400 wiring diagram (See the Electrical Diagrams section of manual.)  
IDEALARC CV-400  
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F-17  
F-17  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)  
FIGURE F.5 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS  
TO MAIN TRANSFORMER LOCATIONS  
TEST PROCEDURE  
1. Set the ON/OFF power switch to OFF.  
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  
top and sides and the reconnect panel  
cover.  
a. Make sure the input contactor (CR1)  
energizes and the fan runs.  
7. Test with an AC voltmeter for proper main  
input supply voltage to the line side of the  
input contactor (CR1). See the Wiring  
Diagram.  
4. Inspect the input contactor, reconnect  
panel, and primary leads to the main trans-  
former for loose or faulty connections. See  
Figure F.5.  
a. L1 to L2.  
b. L2 to L3.  
c. L1 to L3.  
a. Confirm that the reconnect panel is  
connected properly for the three-phase  
main input power supplied to the  
machine. See the reconnect panel  
connection diagram located on the  
inside of the input box assembly  
access door.  
IDEALARC CV-400  
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F-18  
F-18  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)  
FIGURE F.6 – MAIN SECONDARY LEAD TEST POINTS  
8. Read the meter.  
11. Test with an AC voltmeter for approximate-  
ly 42VAC across each of the three main  
secondary start leads located at the  
SCR/Diode Rectifier Bridge. Remove the  
red insulating paint to achieve good con-  
tact if necessary. See Figure F.6. See the  
Wiring Diagram.  
a. If proper voltage is present for all three  
phases, proper main input supply volt-  
age is being supplied.  
b. If proper voltage is not present in any  
or all of the three phases, check input  
fuses and leads.  
a. If one or more of the above voltage  
tests are incorrect, check for loose or  
faulty connections.  
9. Test with an AC voltmeter for proper main  
input supply voltage from the output side of  
the input contactor (CR1). See the Wiring  
Diagram and Figure F.5.  
b. If the connections are good, then the  
main transformer may be faulty. Re-  
place the main transformer.  
a. T1 to T2.  
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  
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F-19  
F-19  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)  
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  
76  
77  
B=GND  
L
I=41  
N
C=2  
H=21  
D=4  
G=75  
E=77  
F=76  
M
12. Test for 115VAC between leads #31 and  
#32 on the terminal strip. Also test for  
42VAC between pin K (lead #42) and pin I  
(lead 41) in the 14-pin amphenol. See  
Figure F.7.  
13. Test with an AC voltmeter for 21VAC for  
each phase angle winding at plug P1 on  
the control board as shown in Figure F.8  
and the accompanying table.  
NOTE: If the main input supply voltage  
varies, the main transformer voltages will  
vary proportionately.  
a. Remove the sheet metal screws from  
the control box cover with the 5/16”  
nut driver and flip the cover down. It  
does not have to be completely  
removed to perform the tests.  
a. If the voltage is low, remove plug P1  
and recheck the voltage for 21VAC. If  
the reading is normal, the control board  
may be faulty. Replace the control  
board.  
b. If the above voltage checks are incor-  
rect, check for loose or faulty wiring.  
Check continuity.  
b. If one or more of the voltage tests are  
incorrect, check for loose or faulty  
wiring.  
c. If the wiring is good, then the main  
transformer may be faulty. Replace the  
main transformer.  
c. If the wiring is good, then the main  
transformer may be faulty. Replace the  
main transformer.  
IDEALARC CV-400  
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F-20  
F-20  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER (T1) VOLTAGE TEST (continued)  
FIGURE F.8 – CONTROL BOARD PLUG P1 LOCATION  
G2629-[  
]
CV-400/CV-500-I CONTROL  
#203  
#204  
#201  
#202  
Plug P3  
Plug P1  
Plug P1 PHASE ANGLE WINDING VOLTAGES  
From Lead #  
To Lead #  
204  
Expected VAC  
21 VAC  
201  
202  
203  
204  
21 VAC  
204  
21 VAC  
IDEALARC CV-400  
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F-21  
F-21  
TROUBLESHOOTING & REPAIR  
STATIC SCR/DIODE RECTIFIER BRIDGE 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 elec-  
trical 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 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 wiring diagrams (See the Electrical Diagrams section of this manual.)  
IDEALARC CV-400  
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F-22  
F-22  
TROUBLESHOOTING & REPAIR  
STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued)  
FIGURE F.9 – CONTROL BOARD AND SNUBBER BOARD PLUG LOCATIONS  
G2629-[  
]
CV-400/CV-500-I CONTROL  
#203  
Plug P5  
Plug P3  
#204  
#202  
#201  
M15370-[  
] SNUBBER  
Plug P1  
TEST PROCEDURE  
1. Disconnect the main input supply power to  
the machine.  
5. Locate and remove molex plug P5 from the  
snubber board. See Figure F.9.  
2. With the 5/16” nut driver, remove the case  
top and sides.  
6. Locate and remove lead #204 from resistor  
R2 (7.5 ohms, 100 watts). See Figure F.14.  
3. Disconnect the welding cables from the  
welding output terminals.  
7. Using the 9/16” wrench, remove the positive  
capacitor strap lead and small lead terminal  
from the rectifier plate and output shunt junc-  
tion. See Figure F.10.  
4. Locate and remove molex plug P3 from the  
control board. See Figure F.9.  
FIGURE F.10 – CAPACITOR STRAP LEAD CONNECTIONS  
POSITIVE  
CAPACITOR  
STRAP LEAD  
SMALL LEAD  
TERMINAL  
IDEALARC CV-400  
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F-23  
F-23  
TROUBLESHOOTING & REPAIR  
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  
heat sink test points. See Figure F.11.  
a. Reverse the meter leads and measure  
the resistance from cathode (+probe)  
to anode (-probe) of diode D1. The  
resistance should be high. See Figure  
F.11.  
NOTE: Do not disassemble the heat sink.  
9. Measure the resistance from the anode to  
the cathode of SCR 1 using an analog  
volt/ohmmeter (multimeter) set at R x 1000  
scale. See Figure F.11.  
b. If a low resistance is measured in both  
meter polarities, diode D1 is shorted.  
Replace diode D1.  
a. Reverse the meter leads and measure  
the resistance from the cathode to the  
anode of SCR 1. See Figure F.11.  
c. If a high resistance is measured in both  
meter polarities, diode D1 is open.  
Replace diode D1.  
b. If a low resistance is measured in  
either meter polarity, SCR 1 is faulty.  
Replace SCR 1.  
12. Test diodes D2, D3 and D4 for proper oper-  
ation using the same procedure described  
in Step 11.  
10. Test the resistance of SCR 2 and SCR 3  
using the same procedure described in  
Step 9.  
13. Reconnect all leads and molex plugs.  
14. If this test did not identify the problem or to  
further test the SCRs, go to the Active  
SCR Test.  
11. Measure the resistance of diode D1 from  
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  
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F-24  
F-24  
TROUBLESHOOTING & REPAIR  
ACTIVE SCR 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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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 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 wiring diagrams (See the Electrical Diagrams section of this manual.)  
IDEALARC CV-400  
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F-25  
F-25  
TROUBLESHOOTING & REPAIR  
ACTIVE SCR TEST (continued)  
FIGURE F.13 – SNUBBER BOARD  
PLUG P5 LOCATION  
FIGURE F.12 – CONTROL BOARD PLUG  
P1 AND P3 LOCATIONS  
G2629-[  
]
CV-400/CV-500-I CONTROL  
#203  
Plug P5  
Plug P3  
#204  
#202  
#201  
M15370-[  
] SNUBBER  
Plug P1  
FIGURE F.14 – RESISTOR R2 LOCATION  
TEST PROCEDURE  
1. Disconnect the main input supply power to  
the machine.  
5. Locate and remove molex plug P5 from the  
snubber board. See Figure F.13.  
2. With the 5/16” nut driver, remove the case  
top and sides. Remove the screws holding  
the front panel and lower the panel.  
6. Locate and remove lead #204 from resistor  
R2 (7.5 ohms, 100 Watts). See Figure F.14.  
7. Using 9/16” wrench, remove the positive  
capacitor strap lead and small lead terminal  
from the positive rectifier plate and output  
shunt junction. See Figure F.10.  
3. Disconnect the welding cables from the  
welding output terminals.  
4. Locate and remove molex plug P3 from the  
control board. See Figure F.12.  
IDEALARC CV-400  
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F-26  
F-26  
TROUBLESHOOTING & REPAIR  
ACTIVE SCR TEST (continued)  
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  
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F-27  
F-27  
TROUBLESHOOTING & REPAIR  
ACTIVE SCR TEST (continued)  
FIGURE F.16 – SCR TESTER CIRCUIT AND SCR CONNECTIONS  
9. Construct the circuit shown in Figure F.16.  
One 6-volt lantern battery can be used., Set  
voltmeter scale low, at approximately 0-5  
volts or 0-10 volts.  
NOTE: Be sure the battery is function-  
ing properly. A low battery can affect the  
results of the test. Repeat Battery Test  
Procedure in Step 10 if needed.  
10. Test the voltage level of the battery. Short  
leads (A) and (C). Close switch SW-1.  
Battery voltage should be 4.5 volts or higher.  
If lower, replace the battery.  
16. Open switch SW-1.  
17. Reconnect the tester leads. See Figure F.16.  
a. Connect tester lead (A) to the cathode.  
b. Connect tester lead (C) to the anode.  
c. Disconnect test lead (G) from the gate.  
18. Close switch SW-1.  
11. Connect the tester to the SCR 1 as shown in  
Figure F.16.  
a. Connect tester lead (A) to the anode.  
b. Connect tester lead (C) to the cathode.  
c. Connect tester lead (G) to the gate.  
12. Close switch SW-1.  
19. Read meter for zero voltage.  
a. If the voltage is zero, the SCR is func-  
tioning.  
NOTE: Switch SW-2 should be open.  
13. Read meter for zero voltage.  
b. If the voltage is higher than zero, the  
SCR is shorted.  
20. Perform the Active Test Procedure outlined  
in Steps 11-19 for SCRs 2 and 3.  
a. If the voltage reading is higher than zero,  
the SCR is shorted.  
21. Replace all SCR assemblies that do not pass  
the above tests.  
14. Close or keep closed switch SW-1.  
15. Close switch SW-2 for 2 seconds. Release  
and read meter.  
22. Replace all molex plugs onto the control  
board and snubber board. Reconnect posi-  
tive capacitor lead and small lead terminal.  
a. If the voltage is 3-6 volts while the switch  
is closed and after the switch is open,  
the SCR is functioning.  
23. Reconnect lead #204 to resistor R2.  
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  
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F-28  
F-28  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM  
MAXIMUM OUTPUT SETTING – NO LOAD  
CH1  
0 volts  
2 ms  
20 volts  
This is the typical DC open circuit  
voltage waveform generated from a  
properly operating machine. Note  
that each vertical division represents  
20 volts and that each horizontal divi-  
sion represents 2 milliseconds in  
time.  
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  
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F-29  
F-29  
TROUBLESHOOTING & REPAIR  
TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
This is the typical DC open circuit  
voltage waveform generated from a  
properly operating machine. Note  
that each vertical division represents  
20 volts and that each horizontal divi-  
sion represents 5 milliseconds in  
time. The machine was loaded with  
a resistance grid bank. The CV-400  
meters read 400 amps at 36 VDC.  
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.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
IDEALARC CV-400  
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F-30  
F-30  
TROUBLESHOOTING & REPAIR  
TYPICAL SCR GATE VOLTAGE WAVEFORM  
MAXIMUM OUTPUT SETTING – NO LOAD  
CH1  
0 volts  
5 ms  
2 volts  
This is the typical SCR gate pulse  
voltage waveform. The machine was  
in an open circuit condition (no load)  
and operating properly. Note that  
each vertical division represents 2  
volts and that each horizontal division  
represents 5 milliseconds in time.  
Note: Scope probes connected at  
SCR gate and cathode: (+) probe to  
gate, (-) probe to cathode.  
SCOPE SETTINGS  
Volts/Div.......................2V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
IDEALARC CV-400  
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F-31  
F-31  
TROUBLESHOOTING & REPAIR  
ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADED  
ONE OUTPUT SCR NOT FUNCTIONING  
CH1  
0 volts  
5 ms  
20 volts  
This is NOT the typical DC output  
voltage waveform. One output SCR  
is not functioning. Note the “ripple”  
in the waveform. 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.  
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.....5 ms/Div.  
Coupling ............................DC  
Trigger .........................Internal  
IDEALARC CV-400  
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F-32  
F-32  
TROUBLESHOOTING & REPAIR  
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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  
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  
7/16” Socket wrench  
Low pressure air source  
IDEALARC CV-400  
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F-33  
F-33  
TROUBLESHOOTING & REPAIR  
INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued)  
FIGURE F.17 – INPUT CONTACTOR CLEANING AND REMOVAL  
1. INPUT SUPPLY LINE  
2. INPUT CONTACTOR CR1  
3. RECONNECT PANEL  
CLEANING PROCEDURE  
CONTACTOR REPLACEMENT  
PROCEDURE  
1. Remove the main input supply power to the  
machine and remove the input access panel.  
1. Disconnect main input supply power to the  
machine.  
2. Locate and get access to the input contac-  
tor (CR1) in the input box. See Figure F.17.  
2. Locate and get access to the input contac-  
tor (CR1) in the input box. See Figure F.17.  
3. Remove the input contactor cover plate  
using a phillips head screwdriver.  
3. Disconnect the main input supply power  
leads L1, L2, and L3 to the input contactor.  
Remove the control transformer primary  
leads H1, H2 or H3 (dependent on input volt-  
age) from L1 and L3 terminals on the input  
side of the contactor.  
WARNING  
Do not apply input power to  
the machine with the input  
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  
input contactor coil.  
Diagram.  
See the Wiring  
4. Blow out any dirt or dust in or around the  
contacts with a low pressure air stream.  
6. Disconnect the leads from the input contac-  
tor coil (leads X1, #232 and #233). See the  
Wiring Diagram.  
5. Inspect the contacts for signs of excessive  
wear, pitting, or contacts fused (stuck)  
together.  
7. Remove the three self-tapping mounting  
screws using a 5/16” socket wrench. See  
Figure F.17.  
a. If any of these conditions are present,  
replace the input contactor assembly.  
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  
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F-34  
F-34  
TROUBLESHOOTING & REPAIR  
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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  
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  
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F-35  
F-35  
TROUBLESHOOTING & REPAIR  
FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued)  
FIGURE F.18 – FAN MOTOR MOUNTING DETAILS  
PROCEDURE  
1. Remove the main input supply power to the  
machine.  
5. Remove the four mounting nuts and associ-  
ated flat and lock washers that hold the  
motor to the mounting bracket. See Figure  
F.18.  
2. Using the 5/16” nut driver, remove the case  
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  
associated flat and lock washers.  
NOTE: You may need to loosen the  
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  
will require cutting the wires or “breaking the  
splice.”  
9. Reattach the fan blade, if it was removed  
earlier, using the Allen head wrench to  
tighten it to the motor shaft.  
10. Install the case top and sides.  
IDEALARC CV-400  
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F-36  
F-36  
TROUBLESHOOTING & REPAIR  
SCR/DIODE RECTIFIER ASSEMBLY  
REMOVAL AND REPLACEMENT  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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  
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  
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F-37  
F-37  
TROUBLESHOOTING & REPAIR  
SCR/DIODE RECTIFIER ASSEMBLY  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.19 – SCR/DIODE ASSEMBLY DETAILS  
PROCEDURE  
assembly removal. Clear any necessary  
leads that might hinder removal.  
1. Remove the main input supply power to the  
machine.  
12. For reassembly, carefully place the SCR/  
diode assembly into position on the mount-  
ing bracket and reinstall the washers and  
nuts. Tighten the front panel to base if it was  
loosened earlier.  
2. With the 5/16” nut driver, remove the case  
top and sides.  
3. Remove the glastic stiffeners (one on right  
side-two on left side). See Figure F.19.  
4. Remove lead #220 from the right side of the  
negative heat sink plate.  
13. Replace and tighten the four nuts and lock-  
washers that hold the SCR/diode assembly  
to the mounting brackets.  
5. Remove the positive capacitor lead and  
shunt from the positive heat sink plate. See  
Figure F.19.  
14. Reattach the three heavy aluminum sec-  
ondary leads to the SCR finned heat sinks.  
Apply a thin coating of Dow Corning 340  
heat sink compound (Lincoln E1868) to con-  
nection points.  
6. Remove the choke and negative capacitor  
leads from the left side of the negative heat  
sink plate. See Figure F.19.  
15. Connect the green ground lead to the front  
panel, lead #225 to the negative output lead,  
and lead #224 to the positive output lead.  
7. Remove the gate leads from the control  
board (plug P3).  
8. Remove plug P5 from the snubber board.  
Also remove lead #224 from the positive  
output lead. Remove lead #225 from the  
negative output lead. Remove the green  
ground lead from the front panel.  
16. Connect plug P5 to the snubber board and  
plug P3 to the control board.  
17. Connect the choke and negative capacitor  
lead to the left side of the negative heat sink  
plate. See Figure F.19. Apply a thin coating  
of Dow Corning 340 heat sink compound  
(Lincoln E1868) to connection points.  
9. Remove the three heavy aluminum sec-  
ondary leads from the SCR finned heat sinks.  
10. Remove the four nuts and associated wash-  
ers that hold the SCR/diode assembly to the  
mounting brackets.  
18. Connect the positive capacitor lead and  
shunt to the positive heat sink plate. See  
Figure F.19.  
11. Carefully lift and remove the SCR/diode heat  
sink assembly from the machine. Note: It  
may be necessary to loosen the four sheet  
metal screws that hold the front panel to the  
base. Carefully lift and pull out the front  
panel to allow clearance for SCR/diode  
19. Install the glastic stiffeners to the left and  
right sides. See Figure F.19. Apply a thin  
coating of Dow Corning 340 heat sink com-  
pound (Lincoln E1868) to connection points.  
20. Install the case top and sides.  
IDEALARC CV-400  
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F-38  
F-38  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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  
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  
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F-39  
F-39  
TROUBLESHOOTING & REPAIR  
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  
SCR mounting surface, using a putty knife or  
similar tool. DO NOT SCRATCH THE SCR  
MOUNTING SURFACE.  
fier, note toward which heat sink the outer metal  
ring of the power SCR is mounted. Also, note  
the positioning of the gate lead of the SCR.  
Failure to reinstall the new SCR in the same ori-  
entation as the original may result in subsequent  
damage to the new SCR and other components  
of the welder. See Figure F.20.  
6. Polish each heat sink’s mounting surface  
using NO. 000 fine steel wool. Wipe surface  
clean with a lint-free cloth or paper towel.  
7. Inspect the mounting surfaces of each new  
SCR.  
CAUTION  
a. Remove all burrs and wipe clean. Do  
not use steel wool or any abrasive  
cleanser on the SCR mounting surfaces.  
The unclamping and clamping procedure out-  
lined below is critical for the prevention of inter-  
nal SCR damage. Failure to follow this proce-  
dure may result in subsequent damage of the  
SCR. Handle all SCRs with care.  
8. Apply a thin (0.001” to 0.003”) layer of PEN-  
ETROX A-13 (Lincoln Electric #E2529) or  
PENETROX A, heat sink compound, to each  
heat sink’s SCR mounting surface.  
a. Care must be used to prevent foreign  
material contamination of the SCR to  
heat sink junction.  
PROCEDURE  
1. Remove the main input supply power to the  
machine.  
9. Place the new SCR between the heat sinks.  
Be sure that the outer metal ring of the SCR  
is facing toward the same heat sink as the  
old SCR’s metal ring. Be sure that the roll  
pin of the heat sink engages the “hole” in the  
SCR. The SCR contact surfaces must sit flat  
against both heat sink surfaces.  
2. Perform  
the  
SCR/Diode  
Rectifier  
Assembly Removal and Replacement pro-  
cedure.  
3. Alternately loosen nuts 1/2 turn each until  
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.  
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F-40  
F-40  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.22 – CLAMP ASSEMBLY  
FIGURE F.21 – 1/2” WIDE LEAF SPRING  
10. Go to the procedure below that matches your  
machine’s cap screws. NOTE WHICH THREAD IS  
ON YOUR CAP SCREWS BEFORE 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.  
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F-41  
F-41  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
CLAMPING PROCEDURE  
FOR 1/4-28 CAP SCREWS  
CLAMPING PROCEDURE  
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  
thread or new SCR will be damaged.  
Do not use cap screws with any other type  
thread or new SCR will be damaged.  
Do not over tighten cap screws. The leaf spring  
will apply the required clamping force to the  
SCR.  
Do not over tighten cap screws. The leaf spring  
will apply the required clamping force to the  
SCR.  
1. Do not turn the nuts. While holding the nuts  
stationary, turn the cap screws only with the  
following procedure.  
1. Do not turn the nuts. While holding the nuts  
stationary, turn the cap screws only with the  
following procedure.  
2. Tighten first cap screw 1/4 turn.  
3. Tighten second cap screw 1/2 turn.  
4. Tighten first cap screw 1/2 turn.  
5. Tighten second cap screw 1/2 turn.  
6. Tighten first cap screw 1/4 turn. Stop.  
2. Tighten first cap screw 1/4 turn.  
3. Tighten second cap screw 1/2 turn.  
4. Tighten first cap screw 1/2 turn.  
5. Tighten second 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.  
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F-42  
F-42  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.23 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING  
STEEL PRESSURE PAD  
HOUSING  
PROCEDURE FOR THE  
5/8 INCH WIDE SPRING  
FIGURE F.24 – CLAMP ASSEMBLY  
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.  
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F-43  
F-43  
TROUBLESHOOTING & REPAIR  
SCR REMOVAL AND REPLACEMENT (continued)  
CLAMPING PROCEDURE  
FOR 1/4-28 CAP SCREWS  
CLAMPING PROCEDURE  
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  
thread or new SCR will be damaged.  
Do not use cap screws with any other type  
thread or new SCR will be damaged.  
Do not over tighten cap screws. The leaf spring  
will apply the required clamping force to the  
SCR.  
Do not over tighten cap screws. The leaf spring  
will apply the required clamping force to the  
SCR.  
1. Do not turn the nuts. While holding the nuts  
stationary, turn the cap screws only with the  
following procedure.  
1. Do not turn the nuts. While holding the nuts  
stationary, turn the cap screws only with the  
following procedure.  
2. Tighten first cap screw 1/4 turn.  
3. Tighten second cap screw 1/2 turn.  
4. Tighten first cap screw 1/2 turn.  
5. Tighten second cap screw 1/2 turn.  
6. Tighten first cap screw 1/2 turn.  
7. Tighten second cap screw 1/4 turn. STOP.  
2. Tighten first cap screw 1/4 turn.  
3. Tighten second cap screw 1/2 turn.  
4. Tighten first cap screw 1/2 turn.  
5. Tighten second cap screw 1/4 turn.  
6. Tighten first cap screw 1/8 turn.  
7. Tighten second cap screw 1/8 turn. STOP.  
8. Assembly now has the proper clamping  
force.  
8. Assembly now has the proper clamping  
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.  
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F-44  
F-44  
TROUBLESHOOTING & REPAIR  
MOUNTING OF STUD TYPE DIODES  
TO ALUMINUM HEAT SINKS  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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  
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  
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F-45  
F-45  
TROUBLESHOOTING & REPAIR  
MOUNTING OF STUD TYPE DIODES  
TO ALUMINUM HEAT SINKS (continued)  
PROCEDURE  
DIODE STUD  
SIZE  
FOOT-  
POUNDS  
INCH-  
POUNDS  
1. Remove the main input supply power to the  
machine.  
3/4-16  
3/8-24  
1/4-28  
25-27  
10±.5  
300-324  
125+0/-5  
22-25  
2. With the 5/16” nut driver, remove the case  
top and sides.  
3. Loosen the appropriate diode nut and  
remove the diode that is to be replaced.  
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.  
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F-46  
F-46  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL AND REPLACEMENT  
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 elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
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  
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” Socket wrench  
9/16” Box end wrench  
1/2” Socket wrench  
1/2” Box end wrench  
3/8” Nut driver or socket wrench  
9/16” Deep well socket wrench  
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F-47  
F-47  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)  
FIGURE F.25 – LIFT BAIL REMOVAL  
8. Using the 9/16” socket wrench, remove the  
four bolts (left and right) mounting the lift bail  
to the transformer top and bottom irons.  
REMOVAL OF LIFT BAIL  
1. Remove the main input supply power to the  
machine.  
9. Using the 9/16” socket wrench, remove the  
four bolts, flat washers, and lock washers  
mounting the lift bail assembly to the base of  
the machine.  
2. With the 5/16” nut driver, remove the case  
top and sides.  
3. Remove the two fiber baffles from the left  
and right sides of the lift bail adjacent to the  
main transformer. 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  
machine.  
5. Remove the positive capacitor strap from  
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.)  
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F-48  
F-48  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)  
FIGURE F.26 – CHOKE REMOVAL  
CHOKE  
LEADS  
TOP  
"E" IRON  
GLASTIC  
STIFFENERS  
THRU-BOLTS  
(4)  
BOTTOM  
"E" IRON  
REMOVAL OF CHOKE AND TOP  
IRON ASSEMBLY  
1. Remove the three (two left and one right)  
glastic stiffeners connecting the negative rec-  
tifier plate and choke assembly to the main  
transformer thru-bolts. See Figure F.26.  
5. Using a hoist, carefully lift the choke and top  
iron assembly out and clear of the trans-  
former coils.  
NOTE: The coils may be “stuck” to the top iron  
and may require some careful prying to  
dislodge them. Depending upon which  
coil(s) are to be replaced, it may be  
advantageous to remove some of the  
“stuck” coils with the top iron.  
2. Remove the top choke lead from the negative  
rectifier plate.  
3. Remove the bottom choke lead from the neg-  
ative output terminal.  
4. Using the 9/16” deep well socket wrench,  
remove the four thru-bolts that clamp the top  
“E” iron and choke assembly to the bottom  
“E” iron. NOTE: for easier reassembly, clean  
the threads.  
6. The leads from the coils that are to be  
removed and/or replaced must be discon-  
nected. See the Wiring Diagram.  
When aluminum leads are re-connected, apply a  
thin layer of Dow Corning 340 Heat Sink  
Compound (Lincoln E1868) to mating surfaces.  
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F-49  
F-49  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)  
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.  
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F-50  
F-50  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)  
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  
three legs of the bottom iron assembly. The coils  
must be in correct position (left, center, right).  
Place the coils so that the leads come out at the  
back of the machine. See Figure F.28 for proper  
positioning.  
7. Place insulation (Lincoln Electric part number  
S20728) on top of each of the three secondary  
coils. The longer side of the insulation should be  
placed toward the front of the machine, where the  
secondary start and finish leads come out. See  
Figure F.29.  
4. Place insulation (Lincoln Electric part number  
S20728) on top of each of the three primary coils.  
The longer side of the insulation should be placed  
toward the front of the machine. See Figure F.29  
for the location of this insulation  
8. Install the three top primary coils, noting which is  
right, left, and center. Leads should come out at  
the back of the machine. See Figure F.28 for prop-  
er positioning. The coils must be in correct position  
(left, center, right).  
5. Place the three secondary coils on top of the insu-  
lation installed in Step 4. The leads should come  
out at the front of the machine with the short leads  
on top. See F.28 for proper positioning.  
9. Install the top iron (lamination) and choke assem-  
bly. With the 9/16” deep well socket wrench,  
reassemble the four thru-bolts that clamp the top  
“E” iron to the bottom “E” iron. Lightly tap on the  
top of the iron with a hammer before tightening.  
Tighten the nuts and thru bolts to 19-25 lb-ft.  
6. Insert shims (Lincoln Electric part number  
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 CENTER  
TOP RIGHT  
TOP LEFT  
SECONDARY COIL ASSEMBLY  
PRIMARY COIL (BOTTOM)  
INSULATION  
SHIMS  
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F-51  
F-51  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)  
FIGURE F.30 – PRIMARY THERMOSTAT LOCATION  
TOP VIEW  
THERMOSTAT  
INSULATION  
FRONT VIEW  
10. Mount the primary thermostat to the lead  
end coil nose. See Figure F.30. Place a  
small amount of Lincoln Electric E1603  
Epoxy between the coil nose and the coil  
insulation and between the insulation and  
the thermostat. Hold the thermostat in  
place with E2381 (.375” wide) tape. If nec-  
essary, after assembly protect the thermo-  
stat terminals with E2547 terminal boots.  
11. If necessary, trim off excess secondary lead  
stickout and TIG weld the leads together.  
See Figure F.31.  
FIGURE F.31 – SECONDARY LEAD TRIM AND WELD DETAIL  
TIG WELD  
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F-52  
F-52  
TROUBLESHOOTING & REPAIR  
MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued)  
REASSEMBLING THE MAIN  
REASSEMBLE THE LIFT BAIL  
TRANSFORMER INTO THE MACHINE  
1. Carefully position the lift bail onto the machine  
base. Using the 9/16” socket wrench, attach the lift  
bail to the base of the machine with four bolts, flat  
washers, and lock washers.  
NOTE: The following procedure assumes you have  
completely reassembled the transformer coils  
as described in the procedure above. The  
lower iron has remained in place in the  
machine. See Figures F.25 and F.26.  
2. Using the 9/16” socket wrench, attach the lift bail to  
the transformer top and bottom irons with four  
bolts.  
1. Attach the bottom choke lead to the negative out-  
put terminal.  
3. Attach the sheet metal screw that holds the capac-  
itor bank assembly to the case back.  
2. Attach the top choke lead to the negative rectifier  
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.  
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F-53  
F-53  
TROUBLESHOOTING & REPAIR  
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  
200/3/60  
Maximum Idle Amps  
Maximum Idle KW  
10.9  
10.5  
9.9  
9.5  
5.8  
5.5  
5.3  
5.0  
4.8  
4.4  
3.8  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
208/3/60  
220/3/60  
230/3/60  
380/3/60  
400/3/60  
415/3/60  
440/3/60  
460/3/60  
500/3/60  
575/3/60  
200/3/50  
220/3/50  
230/3/50  
380/3/50  
400/3/50  
415/3/50  
440/3/50  
500/3/50  
19.8  
18.0  
17.2  
10.4  
9.9  
9.5  
9.0  
7.9  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
1.2  
OPEN CIRCUIT VOLTAGES  
Test Points  
Welding Output Terminals  
Input Hertz  
Open Circuit Volts  
43/47VDC  
60  
Welding Ouput Terminals  
50  
43/47VDC  
Auxiliary Output (#31 - #32)  
Auxiliary Output (#31 - #32)  
60  
50  
114/124VAC  
109/119VAC  
Auxiliary Output (#41 - #42)  
Auxiliary Output (#41 - #42)  
60  
50  
43.8/47.5VAC  
42.0/45.6VAC  
Auxiliary Output (#51 - #52)  
50  
220/231VAC  
WELDING OUTPUT LOAD TEST  
Output Control Setting  
Amps  
Volts  
Minimum  
75 to 150  
6 to 11  
Maximum  
525  
more than 41.2  
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F-54  
F-54  
NOTES  
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G-1  
G-1  
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  
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G-2  
G-2  
ELECTRICAL DIAGRAMS  
Wiring Diagram (Codes 10084, 10085, 10086)  
H3  
H4  
380/500 V.  
(SHOWN CONNECTED  
FOR 380 V.)  
DUAL  
&
SINGLE VOLTAGE  
230/400 VOLTAGE  
(SHOWN CONNECTED  
FOR 230 V.)  
220/380/440 VOLTAGE  
TO GROUND  
PER NATIONAL  
ELECTRICAL CODE  
TO GROUND  
PER NATIONAL  
ELECTRICAL CODE  
TO GROUND  
PER NATIONAL  
ELECTRICAL CODE  
N.B.  
UNDER 346 VOLTS  
(SHOWN CONNECTED FOR 220 V.)  
(SHOWN CONNECTED  
FOR LOW VOLTAGE)  
N.B.  
H3  
H3  
N.B.  
TO SUPPLY  
LINES  
TO SUPPLY  
LINES  
RECONNECT PANEL  
TO SUPPLY  
H3  
LINES  
RECONNECT PANEL  
N.B.  
RECONNECT PANEL  
RECONNECT PANEL  
TO SUPPLY  
LINES  
H2  
X1  
H2  
X1  
H2  
X1  
L2  
L1  
H2  
L3  
L1  
L2  
L3  
L2  
L1  
L3  
TO GROUND  
PER NATIONAL  
L3  
L2 L1  
3
2
6
5
X1  
11  
9
8
7
9
8
6
3
11  
3
2
1
18  
3
9
8
W
V
U
5
W
W
V
3
ELECTRICAL  
CODE  
2
2
1
W
V
V
2
10  
12  
10  
12  
17  
16  
1
4
6
5
232  
1
232  
232  
u
U
1
U
4
CR1  
CONTACTOR  
H1  
233  
CR1  
CONTACTOR  
4
CR1  
7
7
CR1  
CONTACTOR  
H1  
FLEX LEAD  
CONTACTOR  
233  
TO PRIMARY  
COILS  
JUMPER  
TO PRIMARY COILS  
COILS  
TO PRIMARY  
233  
H1  
H1  
233  
T0 PRIMARY COILS  
SINGLE VOLTAGE OVER  
345 VOLTS  
FAN MOTOR  
115V  
232  
2A  
51  
TO GROUND PER  
CIRCUIT  
31  
32A  
X1  
H1  
H2  
NATIONAL ELECTRICAL  
BREAKER  
CONNECT OR  
INSULATE AS  
SHOWN ON  
CODE  
10AMP  
THIS CONNECTION  
115V  
X2  
CIRCUIT  
42  
DOES NOT APPEAR ON  
220/380/440V AND  
230/400V NACHINES  
N.B.  
H3  
X1  
50  
H2  
TO SUPPLY  
LINES  
BREAKER  
H3  
H4  
INPUT  
CONNECTION  
DIAGRAM  
52  
42  
L2  
L1  
L3  
2
241  
231  
3
2
1
PRIMARY  
10  
SECONDARY  
THERMOSTAT  
T2 CONTROL  
TRANSFORMER  
42A  
W
V
11  
12  
THERMOSTAT  
TOP  
S
220V  
21V  
42V  
S
115V  
PRIMARY  
41  
41  
232  
N.E.  
8
S
7
U
CR1  
9
231  
4
201  
203  
21V  
AUXILIARY  
COILS  
202  
CONTACTOR  
T1 MAIN  
CAPACITOR  
DISCHARGE  
RELAY  
21V  
41  
H1  
233  
TRANSFORMER  
S
204  
S
S
5
6
3
4
BOTTOM  
PRIMARY  
X1  
X2  
X3  
CAPACITOR  
DISCHARGE  
OPTION  
SEC  
SEC  
SEC  
2
1
16  
17  
18  
10A  
0.5 /50W  
0.5 /50W  
SLOW  
BLOW  
N.A.  
204  
254  
220  
D2  
220  
P5  
220  
221  
222  
223  
1
2
3
4
5
6
C1  
C2  
C3  
C4  
C5  
+
+
+
+
+
N.C.  
D1  
D3  
31,000MFD  
50V EACH  
D4  
204  
SHUNT  
DIODE  
OPTION  
RECTIFIER  
ASSEMBLY  
J5  
225  
SCR2  
SCR3  
SCR1  
SCR2  
+
-
224  
204  
220  
GREEN  
7
8
LEAD NOT PRESENT  
WITH DIODE OPTION  
7.5 /100W  
205 206  
204  
SNUBBER  
BOARD  
G3  
G2  
G1  
204  
3
204  
224  
P3  
P1  
1
2
4
1
P2  
205  
S3  
41  
VOLTMETER  
SWITCH  
1
2
21  
2
3
4
225  
201  
206  
212  
220  
205  
206  
J3  
ELECTRICAL SYMBOLS PER  
E1537  
225  
202  
4
3
4
5
6
21  
5
6
7
8
1
J1  
J2  
2
3
4
4
204  
203  
2
5
6
1
2
3
4
C6  
.0047MFD  
1400V  
2
7
8
4
PIN  
J3  
8
PIN  
31  
32  
7
8
213  
75  
J1 J2 & J5  
240  
CONTROL BOARD  
TS2  
CONNECTOR CAVITY  
NUMBERING SEQUENCE  
(COMPONENT SIDE OF P.C.  
BOARD)  
TS1  
L1  
75  
OUTPUT  
CHOKE  
CONTROL BOARD  
GROUNDING LEAD  
10A  
76  
77  
NOTES  
N.A. CIRCUITRY PRESENT ON  
CAPACITOR DISCHARGE  
CIRCUIT  
32  
BREAKER  
ONLY.  
32A  
240  
Y
N.B. TAPE UP SEPARATELY  
TO PROVIDE AT LEAST  
N.F.  
N.A.  
600  
V
INSULATION.  
212 210 211  
213  
210  
211  
232  
233  
42  
GROUNDING  
STUD  
75  
N.C. CIRCUITRY PRESENT ON  
DIODE OPTION ONLY.  
32  
41  
31  
42  
233  
W
R4  
77  
76  
2
4
77  
231  
10K /2W  
OUTPUT  
CONTROL  
PILOT  
LIGHT  
THERMAL  
PROTECTION  
LIGHT  
N.D. THESE LEADS ARE PRESENT  
WITH METER OPTION ONLY.  
21  
S2  
S1  
75  
OUTPUT CONTROL  
SWITCH  
76  
GREEN  
POWER  
SWITCH  
N.E. 220V WINDING, PLUG  
N.D.  
AND CIRCUIT BREAKER  
ARE PRESENT ONLY  
ON CV500-I.  
224  
224  
205  
225  
206  
N.F. 31 AND 32 ARE NOT  
PRESENT ON EUROPEAN  
AM  
VM  
METERS  
OPTIONAL  
CV500-I  
-
-
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-3  
G-3  
ELECTRICAL DIAGRAMS  
Wiring Diagram (Code 10087)  
230/460/575V.  
(SHOWN CONNECTED FOR 230 V.)  
H3  
H4  
N.B.  
TO SUPPLY  
LINES  
RECONNECT PANEL  
H2  
L1  
L3 L2  
13  
X1  
3
9
8
2
7
1
14  
15  
W
TO GROUND PER NATIONAL  
ELECTRICAL CODE  
N.B.  
4
5
16  
17  
18  
V
U
6
FAN MOTOR  
CR1  
CONTACTOR  
233  
TO PRIMARY  
COILS  
232  
H1  
T1 MAIN  
CONNECT OR  
31  
X1  
TRANSFORMER  
INSULATE AS  
SHOWN ON  
32A  
10AMP  
CIRCUIT  
BREAKER  
H2  
42  
115V  
AUXILIARY  
42  
INPUT  
CONNECTION  
DIAGRAM  
H3  
H4  
COILS  
10  
2
42A  
241  
41  
X2  
231  
11  
12  
PRIMARY  
THERMOSTAT  
SECONDARY  
THERMOSTAT  
42V  
115V  
T2 CONTROL  
TRANSFORMER  
7
8
9
S
S
41  
201  
S
203  
21V  
202  
21V  
TOP  
231  
14  
13  
15  
PRIMARY  
21V  
4
S
CAPACITOR  
DISCHARGE  
RELAY  
204  
S
41  
5
6
4
CAPACITOR  
DISCHARGE  
OPTION  
BOTTOM  
PRIMARY  
X1 SEC  
X2 SEC  
X3 SEC  
1
2
3
N.A.  
16  
18  
17  
10A  
0.5 /50W  
0.5 /50W  
SLOW  
BLOW  
204  
254  
C1  
C2  
C3  
C4  
C5  
+
+
+
+
+
220  
220  
P5  
31,000 MFD  
50V EACH  
1
2
3
4
5
6
220  
221  
222  
223  
N.C.  
D1  
D2  
D3  
D4  
204  
SHUNT  
DIODE  
OPTION  
RECTIFIER  
ASSEMBLY  
J5  
204  
220  
225  
SCR2  
SCR3  
SCR1  
+
-
7.5 /100W  
224  
GREEN  
7
8
LEAD NOT PRESENT  
WITH DIODE OPTION  
205 206  
204  
SNUBBER  
BOARD  
G3  
G2  
G1  
204  
204  
224  
ELECTRICAL SYMBOLS PER  
E1537  
P3  
P1  
1
3
2
4
1
P2  
S3  
41  
VOLTMETER  
SWITCH  
205  
206  
212  
220  
205  
206  
213  
75  
21  
1
2
3
4
5
6
5
6
7
8
1
201  
2
3
4
225  
J3  
2
3
4
1
2
3
4
225  
202  
4
21  
J1  
4
PIN  
J3  
8
J2  
PIN  
&
J2  
4
J1,  
J5  
204  
203  
2
5
6
C6  
CONNECTOR CAVITY  
NUMBERING SEQUENCE  
(COMPONENT SIDE OF P.C.  
BOARD)  
2
.0047MFD  
1400V  
7
8
31  
32  
7
8
240  
CONTROL BOARD  
TS2  
TS1  
NOTES  
N.A.  
CIRCUITRY PRESENT ON  
CAPACITOR DISCHARGE  
ONLY.  
L1  
75  
OUTPUT  
CHOKE  
CONTROL BOARD  
GROUNDING LEAD  
10A  
76  
77  
CIRCUIT  
32  
N.B. TAPE UP SEPARATELY  
TO PROVIDE AT LEAST  
BREAKER  
32A  
600  
V
INSULATION.  
240  
Y
N.C. CIRCUIT PRESENT ON  
DIODE OPTION ONLY.  
N.A.  
212 210 211  
213  
210  
211  
232  
233  
42  
GROUNDING  
STUD  
75  
N.D. THESE LEADS ARE  
PRESENT WITH METER  
OPTION ONLY.  
32  
41  
31  
42  
233  
W
R4  
77  
76  
2
4
77  
231  
10K /2W  
OUTPUT  
CONTROL  
PILOT  
LIGHT  
THERMAL  
PROTECTION  
LIGHT  
21  
S2  
S1  
75  
OUTPUT CONTROL  
SWITCH  
76  
POWER  
GREEN  
SWITCH  
N.D.  
224  
224  
205  
225  
206  
12-9-94F  
L9270  
AM  
VM  
METERS  
OPTIONAL  
-
-
206  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-4  
G-4  
ELECTRICAL DIAGRAMS  
Control PC Board (G2629-1) Layout  
ITEM  
PART No.  
IDENTIFICATION  
REQ’D.  
G2629-1  
CV400  
/
CV500-I CONTROL  
X5  
D48  
D49  
R26  
R27  
R28  
QU1  
M
D10  
C23  
C7  
R17  
R29  
D13  
D16  
Q8  
Q2  
C35  
D7  
R14  
D4  
SCR1  
C1  
R1  
N
R141  
H
X3  
R112  
R11  
R4  
D1  
R10  
R20  
R166  
R169  
R160  
C10  
R163  
DZ1  
R7  
C39  
E
R148  
D65  
QU2  
D11  
D14  
D17  
C8  
R18  
R30  
C40  
D
A
X4  
X2  
X1  
OCI1  
D8  
R15  
D5  
SCR2  
C2  
R2  
R191  
R190  
R40  
R41  
I
R12  
R5  
D2  
R86  
R21  
R167  
R170  
R161  
C11  
R164  
DZ2  
R8  
R82  
C19  
R76  
C24  
R56  
D51  
D66  
D12  
D15  
D18  
D31  
D52  
D32  
D42  
R124  
R149  
R39  
QU3  
G
D33  
R35  
C9  
R19  
R31  
R51  
R50  
D41  
R37  
R36  
R43  
D67  
R158  
R157  
R156  
R159  
C17  
D9  
R16  
D6  
R150  
SCR3  
C3  
R3  
K
R70  
R75  
D35  
D34  
R77  
C38  
C37  
C18  
J
R13  
R6  
D3  
R87  
R22  
R168  
R171  
L
R162  
C12  
R165  
DZ3  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-5  
G-5  
ELECTRICAL DIAGRAMS  
Control PC Board (G2629-1) Schematic  
9 1 L 4 8  
R148  
R144  
R151  
R177  
R178  
R179  
R180  
R181  
R182  
R183  
R184  
R185  
R186  
R187  
R188  
R189  
R143  
R142  
R43  
R38  
R37  
R156  
R60  
R176  
R58  
R59  
R159  
R158  
R153  
R71  
R70  
R115  
R90  
R95  
R50  
R51  
R190  
R94  
R91  
R135  
R137  
R82  
R77  
R93  
R139  
R114  
R112  
R113  
R63  
R64  
R197  
R198  
R199  
R1  
R194  
R195  
R196  
R2  
R3  
R9  
R6  
R8  
R5  
R7  
R4  
R13  
R87  
R11  
R10  
R12  
R86  
R19  
R22  
R17  
R14  
R20  
R16  
R18  
R15  
R21  
R168  
R166  
R171  
R169  
R167  
R170  
R29  
R26  
R30  
R27  
R31  
R28  
R161  
R160  
R163  
R162  
R165  
R164  
9148  
L
7-18-97J  
IDEALARC CV-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-6  
G-6  
ELECTRICAL DIAGRAMS  
Snubber PC Board (M15370-3) Layout  
SNUBBER  
M15370-3  
DESCRIPTION  
ITEM  
PART NO.  
REQD  
C1,C2,C3  
C4,C5  
T11577-68  
T11577-46  
T12733-10  
T13640-12  
T13640-18  
T13640-16  
.68/400  
.05/600  
10 2W  
38J  
3
2
R1,R2,R3  
3
3
2
1
TP1,TP2,TP3  
TP4,TP5  
TP6  
160J  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-7  
G-7  
ELECTRICAL DIAGRAMS  
Snubber PC Board (M15370-3) Schematic  
R1  
R2  
R3  
IDEALARC CV-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-8  
G-8  
NOTES  
IDEALARC CV-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  

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