Lincoln Electric SVM136-A service manual Safety Precautions, Location and Ventilation, Lifting

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A-3

A-3

INSTALLATION

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Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

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.

Only qualified personnel should install, use, or ser- vice this equipment.

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.

STACKING

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.

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.

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LOCATION AND VENTILATION

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.

THE CV-400 carries an IP-21 environmental rating. Locate indoors or shelter from falling water such as rain.

ELECTRICAL INPUT CONNECTIONS

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.

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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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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 InstallationSafety Precautions Location and VentilationLifting 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 Safety Instructions OperationOperating Instructions Design Features Operational Features and ControlsGeneral Description Recommended ProcessesLimitations Welding CapabilityFigure B.1 Case Front Controls Controls and SettingsRemote Control Welding OperationLocal Control Overload Protection Auxiliary PowerIdealarc CV-400 Table of Contents Accessories OPTIONS/ACCESSORIES Factory Installed OptionsField 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 Control Transformer T2 Voltage Test DescriptionMaterials Needed 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
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