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Lincoln Electric SVM136-A service manual IDEALARC CV-400, Service Manual, November

Models: SVM136-A

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SVM136-A

November 1997

IDEALARC ® CV-400

For Machines with Code Numbers 10084 thru 10087

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be in- creased by proper installation . . .

and thoughtful operation on your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL


World’s Leader in Welding and Cutting Products			Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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Lincoln Electric SVM136-A service manual IDEALARC CV-400, Service Manual, November, Return to Master TOC

Contents

SERVICE MANUAL SVM136-AView Safety Info View Safety Info View Safety Info View Safety Info IDEALARC CV-400FOR ENGINE powered equipment SAFETYELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSARC RAYS can burn ELECTRIC SHOCK can killFUMES AND GASES can be dangerous SAFETYCYLINDER may explode if damaged FOR ELECTRICALLY powered equipmentWELDING SPARKS can cause fire or explosion SAFETYSAFETY PRÉCAUTIONS DE SÛRETÉReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCRETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONSParts Manual INSTALLATION SECTION TABLE OF CONTENTSReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTECHNICAL SPECIFICATIONS - IDEALARC CV-400 INSTALLATIONINPUT - THREE PHASE ONLYLOCATION AND VENTILATION SAFETY PRECAUTIONSINSTALLATION Read this entire installation section before you start installationReturn to Section TOC Return to Section TOC INSTALLATIONReturn to Master TOC Return to Master TOC FIGURE A.1 RATING PLATE LOCATIONFIGURE A.3 INPUT POWER SUPPLY CONNECTIONS INSTALLATIONReturn to Section TOC Section TOC FIGURE A.2 REAR PANELOUTPUT CONNECTIONS RECONNECT PROCEDUREINSTALLATION FIGURE A.4 INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZReturn to Section TOC Return to Section TOC Return to Section TOC INSTALLATIONReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC INSTALLATIONReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Section BOPERATION SAFETY INSTRUCTIONSOPERATING INSTRUCTIONS ELECTRIC SHOCK can killOPERATION GENERAL DESCRIPTIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC OPERATIONReturn to Master TOC Return to Master TOC Return to Master TOC Duty CycleOPERATION CONTROLS AND SETTINGSReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCOPERATION WELDING OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCOVERLOAD PROTECTION AUXILIARY POWEROPERATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS ACCESSORIESReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCACCESSORIES OPTIONS/ACCESSORIESFIGURE C.1 REMOTE CONTROL ADAPTER CABLE K864 Return to Section TOC Return to Section TOCACCESSORIES AUTOMATIC WIRE FEEDERSFIGURE C.2 NA-3 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 FEEDERTERMINALACCESSORIES FEEDERTERMINALFIGURE C.3 NA-5 WIRE FEEDER CONNECTION TO THE CV-400 Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC ACCESSORIESReturn to Master TOC Return to Master TOC Return to Master TOC Return to Section TOCACCESSORIES SEMIAUTOMATIC WIRE FEEDERSFIGURE C.4 LN-7 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 FEEDERTERMINALFIGURE C.5 LN-8 OR LN-9 WIRE FEEDER CONNECTION TO THE IDEALARC CV-400 ACCESSORIESReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS MAINTENANCEReturn to Master TOC Section DMAINTENANCE MAINTENANCEROUTINE AND PERIODIC SAFETY PRECAUTIONS11. CASE BACK WITH FAN MOTOR ASSEMBLY MAINTENANCEReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTABLE OF CONTENTS THEORY OF OPERATION SECTIONGENERAL DESCRIPTION to MasterINPUT LINE VOLTAGE, CONTACTOR AND MAIN TRANSFORMER THEORY OF OPERATIONSection TOC Master TOCTHEORY OF OPERATION OUTPUT CONTROL, RECTIFICATION AND FEEDBACKSection TOC Master TOCCIRCUITS PROTECTIVE DEVICES ANDTHEORY OF OPERATION FIGURE E.4 - CV-400 TRIGGER AND THERMAL LIGHT CIRCUITTHEORY OF OPERATION SCR OPERATIONto Section TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTIONReturn to Master TOC HOW TO USE TROUBLESHOOTING GUIDE TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Master TOCSection TOC TROUBLESHOOTING & REPAIRMaster TOC Return toOUTPUT PROBLEMS TROUBLESHOOTING & REPAIRObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR OUTPUT PROBLEMSObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCOUTPUT PROBLEMS TROUBLESHOOTING & REPAIRObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCOUTPUT PROBLEMS TROUBLESHOOTING & REPAIRObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCOUTPUT PROBLEMS TROUBLESHOOTING & REPAIRObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR WELDING PROBLEMSObserve Safety Guidelines Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR CONTROL TRANSFORMER T2 VOLTAGE TESTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR RIGHT SIDE VIEWCONTROL TRANSFORMER T2 VOLTAGE TEST continued Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR INPUT CONTACTOR TESTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCX1, #232 INPUT CONTACTOR TEST continuedTROUBLESHOOTING & REPAIR #233INPUT CONTACTOR TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER T1 VOLTAGE TESTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCMAIN TRANSFORMER T1 VOLTAGE TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCMAIN TRANSFORMER T1 VOLTAGE TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCPlug P1 PHASE ANGLE WINDING VOLTAGES TROUBLESHOOTING & REPAIRMAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F.8 - CONTROL BOARD PLUG P1 LOCATIONTROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TESTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST continuedto Section TOC to Master TOCTROUBLESHOOTING & REPAIR SCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCRSTATIC SCR/DIODE RECTIFIER BRIDGE TEST continued Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR ACTIVE SCR TESTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR ACTIVE SCR TEST continuedReturn to Section TOC Return to Master TOCACTIVE SCR TEST continued TROUBLESHOOTING & REPAIRSCR ANODE REMOVE ANY INSULATING PAINT CATHODE SCR Return to Section TOC Return to Section TOC Return to Section TOCACTIVE SCR TEST continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Master TOCSCOPE SETTINGS MAXIMUM OUTPUT SETTING - NO LOADNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM TROUBLESHOOTING & REPAIRTROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDSCOPE SETTINGS Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORMSCOPE SETTINGS Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM - MACHINE LOADEDSCOPE SETTINGS Return to Section TOC Return to Section TOC Return to Section TOCDESCRIPTION INPUT CONTACTOR CR1 CLEANING/REPLACEMENTMATERIALS NEEDED TROUBLESHOOTING & REPAIRINPUT CONTACTOR CR1 CLEANING/REPLACEMENT continued TROUBLESHOOTING & REPAIRFIGURE F.17 - INPUT CONTACTOR CLEANING AND REMOVAL Return to Section TOC to Section TOCTROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT continuedFIGURE F.19 - SCR/DIODE ASSEMBLY DETAILS Return to Section TOC to Section TOCTROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENTDESCRIPTION MATERIALS NEEDEDPROCEDURE SCR REMOVAL AND REPLACEMENT continuedSPECIAL INSTRUCTIONS TROUBLESHOOTING & REPAIRSCR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING & REPAIRFIGURE F.22 - CLAMP ASSEMBLY Return to Section TOC Return to Section TOC Return to Section TOCSCR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section Return to Section TOC Return to Section TOC Return to Master Return to Master TOC Return to Master TOCSCR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING & REPAIRFIGURE F.23 - HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING HOUSINGSCR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING & REPAIRRemoval and Replacement procedure to Return to Section Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKSReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS continuedSection TOC Master TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENTReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT continuedReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCMAIN TRANSFORMER REMOVAL & REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCMAIN TRANSFORMER REMOVAL & REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCMAIN TRANSFORMER REMOVAL & REPLACEMENT continued TROUBLESHOOTING & REPAIRFIGURE F.28 - COIL LEAD PLACEMENT Return to Section TOCMAIN TRANSFORMER REMOVAL & REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCMAIN TRANSFORMER REMOVAL & REPLACEMENT continued TROUBLESHOOTING & REPAIRReturn to Section Return to Section TOC Return to Section TOC Return to Master Return to Master TOC Return to Master TOCTROUBLESHOOTING & REPAIR RETEST AFTER REPAIRInput Volts/Phase/Hertz Output Control SettingReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectrical Diagrams Section ELECTRICAL DIAGRAMSReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMS Wiring Diagram Codes 10084, 10085Return to Section Return to MasterELECTRICAL DIAGRAMS Wiring Diagram CodeSection TOC Master TOCELECTRICAL DIAGRAMS Control PC Board G2629-1 LayoutReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCELECTRICAL DIAGRAMS Control PC Board G2629-1 Schematicto Section TOC Return to Master TOCELECTRICAL DIAGRAMS Snubber PC Board M15370-3 LayoutM15370-3 SNUBBERELECTRICAL DIAGRAMS Snubber PC Board M15370-3 Schematic38J GENERAL INFORMATION Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC