Lincoln Electric SVM136-A General Description, Recommended Processes, Design Features

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B-3

B-3

OPERATION

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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.

RECOMMENDED PROCESSES

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.

The CV-400 can be connected to wire feeding equip- ment, including:

•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.)

•Semiautomatic wire feeders LN-7, LN-7 GMA, LN8, LN-9, LN-9 GMA, LN-22, LN23P, LN-25, and LN-742.

OPERATIONAL FEATURES AND CONTROLS

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)

•Auxiliary Power Connections for Wire Feeder and Other Equipment (115V and 42V)

•Thermal Protection Indicator Light

•Voltmeter "+" Electrode or "-" Electrode Switch

DESIGN FEATURES

•Input line voltage compensation keeps output con- stant for fluctuations of ±10%.

•SCR control.

•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.

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IDEALARC CV-400

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Contents Idealarc CV-400 California Proposition 65 Warnings SafetyElectric Shock can kill Cylinder may explode if damaged Sûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Idealarc CV-400 InstallationLifting Safety PrecautionsLocation and Ventilation Input Supply Connections Ground ConnectionReturn to Input Wire and Fuse SizeConnect Electrode and Work Leads to Output Terminals Reconnect Procedure Output ConnectionsFigure A.5 Output Terminal Connections Connect Wire Feeders Table of Contents Operation Section Operating Instructions Safety InstructionsOperation Design Features Operational Features and ControlsGeneral Description Recommended ProcessesLimitations Welding CapabilityFigure B.1 Case Front Controls Controls and SettingsLocal Control Remote ControlWelding Operation Overload Protection Auxiliary PowerIdealarc CV-400 Table of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESFactory Installed Options Connecting the NA-3 to the Idealarc CV-400 Automatic Wire FeedersFeederterminal Connecting the NA-5 to the Idealarc CV-400Accessories Connecting the LN-7 to the Idealarc CV-400 Terminal Strip Semiautomatic Wire FeedersConnecting the LN-8 or LN-9 to the Idealarc CV-400 Idealarc CV-400 Table of Contents Maintenance Return to Return to Section TOC Safety Precautions Routine and Periodic MaintenanceFigure D.1 Idealarc CV-400 Table of Contents Theory of Operation Section Input Line VOLTAGE, Contactor and Main Transformer Theory of OperationOutput CONTROL, Rectification and Feedback Figure E.4 CV-400 Trigger and Thermal Light Circuit Protective Devices CircuitsFigure E.5 SCR Operation SCR OperationIdealarc CV-400 Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairElectric Shock can kill PC Board Troubleshooting ProceduresOutput Problems Troubleshooting GuideOutput Problems SCR/Diode Perform the SCR/Diode Bridge SCR/Diode Rectifier Bridge Test Welding Problems Materials Needed Control Transformer T2 Voltage TestDescription Control Transformer T2 Voltage Test Test ProcedureRight Side View Input Contactor Test Input Contactor Test Figure F.4 Input Contactor Test Connections Test for Contact ContinuityMain Transformer T1 Voltage Test Main Transformer T1 Voltage Test Figure F.6 Main Secondary Lead Test Points Blank Main Transformer T1 Voltage Test Static SCR/DIODE Rectifier Bridge Test Static SCR/DIODE Rectifier Bridge Test SCR Anode Remove ANY Insulating Paint Cathode SCR Active SCR Test Active SCR Test Figure F.15 Heat Sink Test Points Figure F.16 SCR Tester Circuit and SCR Connections Normal Open Circuit Voltage Waveform Maximum Output Setting no LoadTypical Output Voltage Waveform Machine Loaded Typical SCR Gate Voltage Waveform Maximum Output Setting no LoadONE Output SCR not Functioning Abnormal Output Voltage Waveform Machine LoadedDescription Input Contactor CR1 CLEANING/REPLACEMENTContactor Replacement Procedure Cleaning ProcedureFAN Motor and Blade Removal and Replacement Procedure FAN Motor and Blade Removal and ReplacementSCR/DIODE Rectifier Assembly Removal and Replacement Removal and Replacement SCR/DIODE Rectifier AssemblySCR Removal and Replacement SCR Removal and Replacement Figure F.21 1/2 Wide Leaf Spring Procedure for the 1/2 Inch Wide SpringClamping Procedure For 1/4-20 CAP Screws Clamping Procedure For 1/4-28 CAP ScrewsInch Wide Spring Procedure forAfter Replacing the SCRs Mounting of Stud Type Diodes To Aluminum Heat Sinks To Aluminum Heat Sinks Mounting of Stud Type DiodesMain Transformer Removal and Replacement Removal of Lift Bail Main Transformer Removal & ReplacementFigure F.26 Choke Removal Removal of Choke and TOP Iron AssemblyFigure F.27 Epoxy MIX Application Areas Reassembly of Transformer CoilsFigure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassemble the Lift Bail Reassembling the Main Transformer Into the MachineInput Idle Amps and Watts Retest After RepairOpen Circuit Voltages Welding Output Load TestIdealarc CV-400 Section G Electrical DiagramsWiring Diagram Codes 10084, 10085 Wiring Diagram Code Control PC Board G2629-1 Layout Control PC Board G2629-1 Schematic Snubber Snubber PC Board M15370-3 Schematic Idealarc CV-400