Lincoln Electric SVM136-A service manual Welding Operation, Local Control, Remote Control

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B-6

B-6

OPERATION

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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.

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.

1.Turn on the main AC input power to the machine.

2.Set the VOLTMETER "+" or "-" switch to the appro- priate position.

-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.

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.)

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.

6.Make the weld.

REMOTE CONTROL

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.

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IDEALARC CV-400

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Contents Idealarc CV-400 Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Idealarc CV-400Lifting Safety PrecautionsLocation and Ventilation Ground Connection Input Supply ConnectionsInput Wire and Fuse Size Return toReconnect Procedure Output Connections Connect Electrode and Work Leads to Output TerminalsFigure A.5 Output Terminal Connections Connect Wire Feeders Table of Contents Operation Section Operating Instructions Safety InstructionsOperation Operational Features and Controls Design FeaturesGeneral Description Recommended ProcessesWelding Capability LimitationsControls and Settings Figure B.1 Case Front ControlsLocal Control Remote ControlWelding Operation Auxiliary Power Overload ProtectionIdealarc CV-400 Table of Contents Accessories Field Installed Options OPTIONS/ACCESSORIESFactory Installed Options Automatic Wire Feeders Connecting the NA-3 to the Idealarc CV-400Connecting the NA-5 to the Idealarc CV-400 FeederterminalAccessories Semiautomatic Wire Feeders Connecting the LN-7 to the Idealarc CV-400 Terminal StripConnecting the LN-8 or LN-9 to the Idealarc CV-400 Idealarc CV-400 Table of Contents Maintenance Safety Precautions Routine and Periodic Maintenance Return to Return to Section TOCFigure D.1 Idealarc CV-400 Table of Contents Theory of Operation Section Theory of Operation Input Line VOLTAGE, Contactor and Main TransformerOutput CONTROL, Rectification and Feedback Protective Devices Circuits Figure E.4 CV-400 Trigger and Thermal Light CircuitSCR Operation Figure E.5 SCR OperationIdealarc CV-400 Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures Electric Shock can killTroubleshooting Guide Output ProblemsOutput Problems SCR/Diode Perform the SCR/Diode Bridge SCR/Diode Rectifier Bridge Test Welding Problems Materials Needed Control Transformer T2 Voltage TestDescription Test Procedure Control Transformer T2 Voltage TestRight Side View Input Contactor Test Input Contactor Test Test for Contact Continuity Figure F.4 Input Contactor Test ConnectionsMain 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 Maximum Output Setting no Load Normal Open Circuit Voltage WaveformTypical Output Voltage Waveform Machine Loaded Maximum Output Setting no Load Typical SCR Gate Voltage WaveformAbnormal Output Voltage Waveform Machine Loaded ONE Output SCR not FunctioningInput Contactor CR1 CLEANING/REPLACEMENT DescriptionCleaning Procedure Contactor Replacement ProcedureFAN Motor and Blade Removal and Replacement FAN Motor and Blade Removal and Replacement ProcedureSCR/DIODE Rectifier Assembly Removal and Replacement SCR/DIODE Rectifier Assembly Removal and ReplacementSCR Removal and Replacement SCR Removal and Replacement Procedure for the 1/2 Inch Wide Spring Figure F.21 1/2 Wide Leaf SpringClamping Procedure For 1/4-28 CAP Screws Clamping Procedure For 1/4-20 CAP ScrewsProcedure for Inch Wide SpringAfter Replacing the SCRs Mounting of Stud Type Diodes To Aluminum Heat Sinks Mounting of Stud Type Diodes To Aluminum Heat SinksMain Transformer Removal and Replacement Main Transformer Removal & Replacement Removal of Lift BailRemoval of Choke and TOP Iron Assembly Figure F.26 Choke RemovalReassembly of Transformer Coils Figure F.27 Epoxy MIX Application AreasFigure F.28 Coil Lead Placement Figure F.30 Primary Thermostat Location Reassembling the Main Transformer Into the Machine Reassemble the Lift BailRetest After Repair Input Idle Amps and WattsOpen Circuit Voltages Welding Output Load TestIdealarc CV-400 Electrical Diagrams Section GWiring 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