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TCV400 

Operator’s Manual

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Date Purchased

Code: 

(ex: 10859)

Serial: 

(ex: U1060512345)

IM10063-A

   |   Issue D ate 12-Feb

© Lincoln Global, Inc.  All Rights Reserved.

For use with machines having Code Numbers: 

11727, 11838

Register your machine:   

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:   

www.lincolnelectric.com/locator

Summary of Contents for TCV400

Page 1: ...859 Serial ex U1060512345 IM10063 A Issue D ate 12 Feb Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 11727 11838 Register your machine www lincolnelectric com register Authorized Service and Distributor Locator www lincolnelectric com locator ...

Page 2: ...AKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is ava...

Page 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 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 ii SAFETY ii FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ... small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 6 c When not welding make certain ...

Page 5: ... the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where th...

Page 6: ...ns Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching...

Page 7: ..._______________________ Date Purchased___________________________________________________________________________ Where Purchased_________________________________________________________________________ Whenever you request replacement parts or information on this equipment always supply the information you have recorded above CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing...

Page 8: ... B 4 Operational Features Controls B 5 B 6 Power Source Operation B 6 Machine and Circuit Protection B 7 ________________________________________________________________________________ MAINTENANCE Section D Safety Precautions D 1 Routine Maintenance D 1 ________________________________________________________________________ TROUBLESHOOTING Section E Safety Precautions E 1 How to Use Troubleshoot...

Page 9: ...Cycle 50 60 100 Standard Voltage 50 60 Hz 200 230 400 460 Volts 39V Amps 500A 450A 400A Operating Temperature 40 C to 40 C Output Range 60A 17V Minimum 500A 39V Maximum RECOMMENDED INPUT WIRE AND FUSE SIZES INPUT VOLTAGE FREQUENCY 200 230 400 460 TYPE 75 C SUPER LAG OR BREAKER SIZE AMPS 1 125 Amp 125 Amp 70 Amp 60 Amp TYPE 75 C GROUND WIRE IN CONDUIT AWG IEC MM2 SIZES 6 14 6 14 8 8 4 10 5 3 TYPE 7...

Page 10: ... C Remove fastening bolts before lifting unit off stacks INPUT POWER CONNECTIONS By removing the rear access panel the three phase input power is connected to the three line terminals on the input contactor and the earth grounding lead to the grounding terminal on the input box floor marked with the symbol Install the reconnect panel jumper links for the proper input voltage per the diagram pasted...

Page 11: ...T CABLES CABLE SIZES FOR COMBINED LENGTH OF ELEC TRODE AND WORK CABLE 400A 100 DUTY CYCLE 500A 50 DUTY CYCLE MACHINE LOAD CABLE LENGTHS UP TO 50 ft 15m 50 to 100 ft 15 30 m 100 150 ft 30 46 m 150 200 ft 46 61 m 200 250 ft 67 76 m 3 0 85 mm2 3 0 85 mm2 3 0 85 mm2 3 0 85 mm2 4 0 107 mm2 2 0 67 mm2 2 0 67 mm2 3 0 85 mm2 3 0 85 mm2 4 0 107 mm2 FIELD INSTALLED OPTIONS ELECTRIC SHOCK can kill Turn the p...

Page 12: ...miautomatic DC constant volt age wire welder DC manual stick welder AC welder with reduced voltage control Do not operate with panels removed Disconnect input power before servicing READ THIS WARNING PROTECT YOURSELF OTHERS FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust at the arc or both to keep fumes and gases from your breathing zone and general area WEL...

Page 13: ...s been designed to use international symbols in describing the function of the various components Below are the symbols used Input Power On Off POWER ON OFF SWITCH Three Phase Power Degree of protection provided by the enclosure RATING PLATE Designates welder complies with International Electrotechnical commission requirements 974 1 IEC 60974 1 IP21S ...

Page 14: ... source It complies with IEC 60974 1 requirements Warning Identification WARNING IDENTIFICATION Signifying the Earth Ground Connection EARTH GROUND CONNECTION Signifying the Chassis Ground Connection CHASSIS GROUND CONNECTION Rectifier Rectified DC Output Constant Voltage Characteristic Line Connection RATING PLATE ...

Page 15: ...vailable only at receptacle pins 19 20 21 and 22 A 15A circuit breaker protects this circuit The 115V AC and the 24V AC are isolated circuits 5 POWER SUPPLY LIGHT A red light on the machine control panel indicates when the tigger is enabled This means auxiliary power is being used 6 THERMAL PROTECTION LIGHT An amber light on the machine control panel indi cates when either of the two protective th...

Page 16: ...of the welder is electronically controlled by SCRʼs instead of mechanical contactors providing extra long life for highly repetitive welding applications SOLID STATE CONTROL SYSTEM The Control PC Board is located behind the control panel which hinges down for easy access to the board The Snubber Printed Circuit Board is mounted on the back of the Front Panel MACHINE COOLING The fan pulls air in th...

Page 17: ... for easy access for internal service or inspection These are removable even though the machines are stacked three high The case rear top section is equipped with a remov able access panel This provides easy access to the input contactor easy connection and reconnection of input leads and easy access for service or inspection Although the machine is designed for use in rain sheltered environments ...

Page 18: ...erloads on the SCR bridge assembly through an electronic protection circuit This circuit senses an overload on the power source and limits the output to 550 amps by phasing back the SCRʼs Protection is provided to protect the circuitry from accidental grounds If the customer accidentally grounds 75 76 or 77 to the positive output lead the output will be reduced to a low value thus preventing any d...

Page 19: ... parts WARNING ROUTINE MAINTENANCE 1 The fan motor has sealed bearings which require no service 2 In extremely dusty locations dirt may clog the air channels causing the welder to run hot Blow out the machine at regular intervals 3 In extremely dusty locations dirt may accumulate on the remote control terminal strip Wipe or blow this terminal strip off at regular intervals This is particularly imp...

Page 20: ...d POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local TAFA Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local TAFA Autho...

Page 21: ...PC Board 5 Primary or secondary thermostats open 1 Terminals 75 76 or 77 grounded to positive output 1 Terminals 75 76 or 77 grounded to negative output 1 Repair or replace 2 Check input power 1 Replace if blown look for reason first 2 Check control transformer T2 and associated leads 3 Check input voltage at contactor 4 Check voltage against instruc tions 5 Replace coil 6 Replace switch 1 Make su...

Page 22: ...ulty Control PC Board 1 One input fuse blown 2 One phase of main transformer open 3 Faulty Control PC Board 1 Input contactor contacts frozen 2 Defective Power I O switch S1 1 Poor work or electrode connec tion 2 Welding leads too small 3 Welding current or voltage too low 4 Defective main SCR bridge 1 Check wiring and control PC Board wiring harness plugs 2 Replace See Procedure for Replacing PC ...

Page 23: ...roper procedures 3 Defective Control PC Board 1 Defective Control PC Board 2 Capacitor s in output circuit failed A failure is indicated if the small vent plug on top of a capac itor is raised or blown out 1 Work connection must be ade quate for application 2 Adjust procedures for improved starting 3 Replace See Procedure for Replacing PC Boards 1 Replace See Procedure for Replacing PC Boards 2 Re...

Page 24: ...nt heat to approximately 550 amps if a short or overload is applied to the machine CHECKING SNUBBER PC BOARD In case of an SCR malfunction or failure the Snubber PC Board should be checked Turn the machine off and remove the sides of the machine Board is mount ed on back of the Front Panel 1 Visually inspect the Board for overheated compo nents or damaged components POWER I O SWITCH CHECK 1 Turn o...

Page 25: ...e leads of the ohmmeter from Step b d A shorted diode will indicate zero or an equally low resistance in both directions An open diode will have an infinite or high resistance in both direc tions and a good diode will have a low resistance in Step b and a much higher resistance in Step c 3 Power Silicon Controlled Rectifier Test The SCR must be mounted in the heat sink when making this test a Conn...

Page 26: ...ay not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 27: ...ay not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 28: ...ram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 29: ... electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 30: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

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