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F-2

DIAGRAMS

F-2

CV-400-I

CONNECTOR CAVITY NUMBERING SEQUENCE

(COMPONENT SIDE OF P. C. BOARD)

ELECTRICAL SYMBOLS

    PER E1537

+

-

L1

SECONDARY

THERMOSTAT

222

223

224

D4

C1

C2

C3

C4

+

+

+

+

R1

SCR2

D2

D5

222

204A

204D

CONTROL

P. C. BOARD

221

6 PIN

4 PIN

8 PIN

SNUBBER/BYPASS

P.C. BOARD

224

224A

224A

 

10A

CIRCUIT

BREAKER

CB1

L1 CHOKE

2

42V

12V

12V

-

204C

204D

204C

277

276

275

B

A

J

C

D

213

214

213

214

206

207

211

212

2

4

10 PIN

S2

M

L

N

G

F

E

H

VOLTMETER

CUSTOMER

CONNECTIONS

WIRE

FEEDER

42 VAC

GROUND

WIRE

FEEDER

RECEPTACLE

205

WIRE FEEDER

S3

3

1

SCR3

D3

SCR1

D1

8

2

3

4

1

7

6

5

213A

213A

OUTPUT

CONTROL

208

209

210

1

2

3

4

J7

METER

P.C.

BOARD

VOLTS / AMPS

215

1

5

7

3

2

4

2

5

3

4

1

6

6

1

5

4

7

3

8

G1

204A

G3

G2

3

1

2

4

J1

J3

J2

J4

21

N.A.

N.A.

 J1

  J4

  J7

 J2

 J5

 J3

J5

J5

223

221

G3

G2

G1

214A

1

2

218

219

400 A. 50mV

SHUNT

J10

2 PIN  J10

224B

224B

224B

213B

213B

213B

NC

(SHOWN IN "VOLTS" POSITION)

7.5 OHM

220 W

214B

214B

s

s

42A

42

41

42

I

K

C1-C4 31,000 MFD EACH

MAIN TRANSFORMER

C

2

41A

41

CIRCUIT

BREAKER

220V

52A

 2A

52

51

2

L2

INPUT SUPPLY

   LINES

 S1 

LINE

SWITCH

*

RECONNECT PANEL

11

8

5

2

* TO A SYSTEM GROUND PER 

  NATIONAL ELECTRICAL CODE.

V

s

FAN

33A

31A

CB3

W

U

L1

L3

13

3

9

6

12

1

7

4

10

10

8

6

10

9

 202

200

203

201

s

50

s

58V

58V

O2 TOP

O1 TOP

O1 TOP

O3 TOP

O3 BOT.

O2 BOT.

O1 BOT.

127V

127V

s

s

RECONNECT

PANEL

230V

RECONNECT

PANEL

400V

 2

 3 1

TO S1 LINE SWITCH

 2

 3 1

TO S1 LINE SWITCH

5

8

2

11

10

12

3

1

9

6

4

5

8

2

11

10

12

3

1

9

6

4

7

7

VOLTMETER

SWITCH

76

77

75

77

76

277

276

S4

(SHOWN IN LOCAL POSITION)

LOCAL/REMOTE SWITCH

R2

10K

CW

376

77

377

376

377

N.A.  WIRING VIEWED FROM REAR OF POTENTIOMETER

 

2

4

2

2

NC

+

-

  

3-10-95H     

    L9857   

WIRING DIAGRAM  CV 400-I  (EUROPE)      

230/400 INPUT VOLTAGES

NOTE:  This diagram is for reference only.   It may not be accurate for all machines covered by this manual.  The specific diag

ram 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.  G

ive the equipment code number..

Содержание IDEALARC CV-400-I

Страница 1: ...PERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 1...

Страница 2: ...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...

Страница 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Страница 4: ...vent 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...

Страница 5: ...i s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pant...

Страница 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Страница 7: ...Connections B 6 Starting the Machine B 7 Adjusting the Output Voltage using the Digital Meter B 7 Local Remote Switch Operation B 7 Auxiliary Power B 7 Overload Protection B 7 Accessories Section C F...

Страница 8: ...60 Duty Cycle 33 100 Duty Cycle 66 33 60 Duty Cycle 68 34 Amps 400 300 400 300 Normal Open Circuit Voltage 10 43 MAX OCV 50 Input kVA NEMA 60 Load 23 6 IEC 60 Load 23 2 NEMA 100 Load 22 9 IEC 100 Loa...

Страница 9: ...s provided for this purpose See the National Electrical Code for details on proper grounding methods Fuse the input circuit with the recommended super lag fuses Choose an input and grounding wire size...

Страница 10: ...the wire feeder receptacle on the CV 400 I c See OUTPUT CONNECTIONS for connection of work and electrode cables Connection of Remote Control K857 NOTE The K864 Remote Control Adapter is required to in...

Страница 11: ...iversal Adapter This adapter plugs into the receptacle and provides the user with short wire leads for connections Refer to the instructions provided with the K867 as well as the wiring diagram for th...

Страница 12: ...f 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 combustibles ARC...

Страница 13: ...tor can choose the optimum output characteristics Solid State Output Contactor no noise no moving parts to wear Digital Voltmeter Ammeter is standard Power on off switch 42 VAC 10 amp auxiliary power...

Страница 14: ...ize this effect F 42 VOLT CIRCUIT BREAKER Protects the 42 volt 41 42 circuit in the wire feeder receptacle from overloads and shorts If this circuit breaker opens the CV 400 I will work normally Howev...

Страница 15: ...switch to This switch has no effect on the welding polarity In fact if the wire feeder being used does not have a voltmeter the setting of this switch has no effect CV 400 I GRAPHIC SYMBOLS THAT APPE...

Страница 16: ...ielding gas C HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION The high inductance connection is more suit able for short arc welding heavier weldments or when using 75 Argon 25 CO2 shield ing gas This conn...

Страница 17: ...ther equipment B CIRCUIT BREAKER Protects the 220 volt auxiliary circuit from over loads and shorts If this breaker opens the CV 400 I will work normally however equipment pow ered by the 220 volt rec...

Страница 18: ...e the Local Remote switch see Figure B 1 in the Remote position The remote control now con trols the output voltage in the manner described above This control may be adjusted while welding to change t...

Страница 19: ...hat can accommodate either one or two gas bottles or one gas bottle and a Magnum water cooler The CV 400 I lifting eye is not functional when the K874 undercarriage is installed WIRE FEEDER SWIVEL MOU...

Страница 20: ...the machine is overloaded the thermostat will open thermal pro tection indicator light will turn on and the output will be zero The fan will continue to run and auxiliary power will still be available...

Страница 21: ...n be conducted with out removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS If you have exhausted all of the recom mended tests in Step 2 Consult your Local Authorized Field Service Fac...

Страница 22: ...nded wfs voltage settings and angle of approach of wire to work b If problem still persists call Local Lincoln Authorized Field Service Facility Allow machine to cool Be sure to provide adequate venti...

Страница 23: ...between 2 4 in wire feeder receptacle 6 If welding with 1 16 aluminum wire and machine is flashing E00 1 Voltage Control misconnected 1 Open in feedback circuitry 2 Faulty PC Board 3 Voltage Adjust p...

Страница 24: ...rrect 1 Thermostat circuit has opened 2 Faulty Control PC Board 1 Faulty Control PC Board 2 Voltage Adjust potentiometer defective 3 Voltage Adjust potentiometer leads open 1 Defective power switch 1...

Страница 25: ...is in the Remote position 2 Faulty Voltage Adjust potentiometer 3 Leads or connections open in control circuit 4 Malfunctioning Remote Control 5 Faulty Control PC board 1 Poor work connection 2 Improp...

Страница 26: ...on the machine 1 Local Remote switch in wrong position 2 Faulty Local Remote switch 3 Faulty Remote Control poten tiometer 4 Leads or connections open in control circuit 5 Faulty Control PC board 1 L...

Страница 27: ...alling a replacement PC board If there is damage to the PC board or if replacing PC board corrects problem return it to the local Lincoln Electric Field Service Shop ELECTRIC SHOCK can kill Have a qua...

Страница 28: ...then ON to return the machine to normal output CHECKING SNUBBER CIRCUIT In case of an SCR malfunction or failure the snubber assembly should be checked Disconnect the input power to the CV 400 I at th...

Страница 29: ...HINES ONLY N B THIS PERMANENT CONNECTION IS MADE AT THE MAIN TRANSFORMER FOR 415V 200 400V AND 380 500V MACHINES ONLY W U L1 L3 1 3 3 9 6 F 12 1 7 4 D 10 10 8 6 10 9 202 200 203 201 s 50 s 58V 58V O2...

Страница 30: ...B 214B s s 42A 42 41 42 I K C1 C4 31 000 MFD EACH MAIN TRANSFORMER C 2 41A 41 CIRCUIT BREAKER 220V 52A 2A 52 51 2 L2 INPUT SUPPLY LINES S1 LINE SWITCH RECONNECT PANEL 11 8 5 2 TO A SYSTEM GROUND PER N...

Страница 31: ...ILL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF ELECTRODE CABLE 14 PIN AMPHENOL POWER SOURCE CV CV...

Страница 32: ...IC SHOCK CAN KILL 6 18 93 NOT USED ON CV CV I POWER SOURCES 42 VAC 115 VAC N E POWER SOURCE FRAME CONNECTION WIRE FEEDER VOLTMETER CONNECTION CONNECTS TO WORK TERMINAL OF POWER SOURCE CONNECT TOGETHER...

Страница 33: ...ERSAL ADAPTER PLUG 75 76 77 GREEN N D Only qualified persons should install use or service this machine using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power So...

Страница 34: ...L POWER SOURCE CV CV I OPTIONAL K857 TO WORK LN 25 WIRE FEEDER REMOTE CONTROL OPTIONAL K484 JUMPER PLUG REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE N C USE OF THE K857 REMOTE CONTROL REQUIRES IN...

Страница 35: ...NOL POWER SOURCE CV CV I TO WORK LN 25 WIRE FEEDER OPTIONAL K484 JUMPER PLUG OPTIONAL K864 REMOTE CONTROL ADAPTER WITH K444 1 OPTION N D N D N C N C CONNECT THE K484 JUMPER PLUG TO THE 14 PIN RECEPTAC...

Страница 36: ...PUT CONTROL OUTPUT CONTROL OUTPUT CONTROL TRIGGER CIRCUIT TRIGGER CIRCUIT SEE APPROPRIATE WIRING DIAGRAM FUNCTION FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY OR MAY NOT BE PRESENT IN YOUR EQU...

Страница 37: ...REAR VIEW 14 PIN BOX RECEPTACLE REAR VIEW AND 14 PIN CABLE PLUG FRONT VIEW K 42 A 32 B GND C 2 L 82 D 4 E 77 M 81 F 76 G 75 N SPARE H 21 I 41 J 31 K 42 J 31 I 41 H 21 N SPARE G 75 F 76 M 81 E 77 D 4...

Страница 38: ...OT IS MARKED FOR THE APPROPRIATE CABLE SIZE PER TABLE BELOW AND SKIN CABLE JACKET TO LENGTH SPECIFIED 1 INCH 25 4mm 35 50 2 mm 35 50 2 1 TWIST MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS 9 20 91...

Страница 39: ...F 11 DIAGRAMS F 11 CV 400 I CONNECTION OF NON LINCOLN WIRE FEEDERS...

Страница 40: ...FOR MOUNTING WELDER DOWN USING 5 16 SCREWS 1 68 N B N B HANDLE CONFIGURATION ON EARLIER MODELS 20 05 509 19 65 499 19 20 487 41 58 1056 26 00 660 3 61 91 12 60 320 42 7 11 99 304 3 90 99 28 7 0 1 00...

Страница 41: ...6 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to...

Страница 42: ...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...

Страница 43: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Страница 44: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...

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