im501-a idealarc cv-400-i · 1.a. turn the engine off before troubleshooting and maintenance work...

IDEALARC CV-400-I

OPERATOR’S MANUAL

IM501-AJune, 2002

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machine Code Numbers 10182, 10183,10084, 10085 & 10086

CV-400-I

• Sales 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 Products •

Copyright © 2002 Lincoln Global Inc.

®

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b.Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the informationyou have recorded above.

vv

viTABLE OF CONTENTSPage

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Select Suitable Location ........................................................................................A-2Input Connections..................................................................................................A-2Field Installed Options ...........................................................................................A-3Required Equipment - Control Cable Connections................................................A-3Output Connections. ..............................................................................................A-3Paralleling .............................................................................................................A-4Connection of Auxiliary Equipment to Wire Feeder Receptacle ............................A-4

Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-2Recommended Processes and Equipment ...........................................................B-2Operational Features and Controls........................................................................B-2Design Features ....................................................................................................B-2Limitations..............................................................................................................B-2Power Source Operation .......................................................................................B-2Duty Cycle .............................................................................................................B-2Controls and Settings ............................................................................................B-3Graphic Symbols ...................................................................................................B-4Output Panel Connections.....................................................................................B-5Case Back Connections ........................................................................................B-6Starting the Machine..............................................................................................B-7Adjusting the Output Voltage using the Digital Meter ............................................B-7Local/Remote Switch Operation ............................................................................B-7Auxiliary Power ......................................................................................................B-7Overload Protection...............................................................................................B-7

Accessories .....................................................................................................Section CFactory/Field Installed Options ..............................................................................C-1Compatible Lincoln Equipment..............................................................................C-1

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1General Maintenance ............................................................................................D-1Machine and Circuit Protection..............................................................................D-1

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Built-in Diagnostic Routines and Error Codes -Troubleshooting Guide.................E-2Machine -Troubleshooting Guide...........................................................................E-3Options -Troubleshooting Guide............................................................................E-6Procedure for Replacing PC Boards......................................................................E-7Control and Meter PC Board Troubleshooting Procedures ...................................E-7Output Voltage, Fault Protection, Snubber Circuit and K857 Remote Control Checks....................E-8

Diagrams ..........................................................................................................Section F

Parts Manual ....................................................................................................Appendix

A-1

CV-400-I

A-1 INSTALLATIONTECHNICAL SPECIFICATIONS – IDEALARC CV-400-I

CodeNumber

10183 (Export, NEMA Rated)

10182 (European, IEC Rated)




Volts at Rated Amperes3632

3429

Auxiliary Power42 Volts AC, 10 Amps

115 Volts AC, 5 Amps (Except Code 10182)220 Volts AC, 2 Amps( All Circuit Breaker Protected)

Idle Current - Amps16/9/8

Input Current atRated Output

100% Duty Cycle 60/35/3060% Duty Cycle 62/36/31

100% Duty Cycle 58/34 60% Duty Cycle 60/33

100% Duty Cycle 35/2660% Duty Cycle 36/27

100% Duty Cycle 3260% Duty Cycle 33

100% Duty Cycle 66/3360% Duty Cycle 68/34

Amps400300

400300

Normal Open Circuit Voltage10-43

MAX OCV: 50

Input kVANEMA 60% Load - 23.6, IEC 60% Load - 23.2

NEMA 100% Load - 22.9, IEC 100% Load - 23.2

Power Factor at Rated Load.80

Power Factor at 100% Load.55

StandardVoltage

220/380/440/3/50/60

230/400/3/50/60

380/500/3/50/60

415/3/50/60

200/400/3/50/60

Duty CycleNEMA Class II (60)100% Duty Cycle

IEC 974-1 60%100% Duty Cycle

Welding Current/Voltage Range(Continuous)

50A/7V - 400A/37VDC

Efficiency at 100% LoadNEMA Rated 78%, IEC Rated 68%

Idle Power825W

INPUT - THREE PHASE ONLY

RATED OUTPUT

OUTPUT

MISC. INFORMATION

Height Width Depth Weight21.5 in. 19.5 in. 27.0 in.

(Lift bail, add 3.12 in) 300 lbs(137 kg)

546 mm 495 mm 686 mm(Lift bail, add 80 mm)

PHYSICAL DIMENSIONS

A-2INSTALLATION

CV-400-I

A-2

Read entire installation section before startinginstallation.

SAFETY PRECAUTIONS

SELECT SUITABLE LOCATION

Place the welder where clean cooling air can freelycirculate in through the side louvers and out throughthe rear louvers. Dirt, dust or any foreign material thatcan be drawn into the welder should be kept at aminimum. Failure to observe these precautions canresult in excessive operating temperatures andnuisance shut-downs. Idealarc CV-400-I powersources carry an IP23 enclosure rating. They arerated for use in damp, dirty environments subject tooccasional falling water such as rain.

STACKING

The CV-400-I may be stacked three-high provided thebottom machine is on a stable, hard, level surface. Besure that the two pins in the roof fit into the slots in thebase of the CV-400-I above it.

TILTING

Do not place the machine on a surface that is inclinedenough to create a risk of the machine falling over.

INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the inputpower is as specified on the welder nameplate.

Gain access to the input reconnect panel by removingthe right case side of the CV-400-I (side nearest to thePower switch.)

Have a qualified electrician connect the input leads toL1, L2, and L3 of the input reconnect panel in accor-dance with the National Electrical Code, all localcodes, and the connection diagram located on theinside of the right case side. Use a three phase line.

The frame of the welder must be grounded. A groundterminal marked with the symbol located on thebase of the machine is provided for this purpose. Seethe National Electrical Code for details on propergrounding methods.

Fuse the input circuit with the recommended super lagfuses. Choose an input and grounding wire sizeaccording to local codes or use the following table."Delay type"1 circuit breakers may be used in place offuses. Using fuses or circuit breakers smaller thanrecommended may result in "nuisance" tripping fromwelder inrush currents even if not welding at high cur-rents.

ELECTRIC SHOCK can kill.• Only qualified personnel should

perform this installation.• Turn the input power OFF at the discon-

nect switch or fuse box before working onthis equipment.

• Turn the Power switch on the CV-400-I“OFF” before connecting or disconnect-ing output cables, wire feeder or remoteconnections, or other equipment.

• Do not touch electrically hot parts.

• Always connect the Idealarc CV-400-Igrounding terminal (located on the welderbase near the reconnect panel) to a goodelectrical earth ground.

WARNING

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

Frequency

208/60

230/60

460/60

575/60

200/50/60

220/50/60

230/50/60

380/50/60

400/50/60

415/50/60

440/50/60

500/50/60

Input

Ampere

Rating on

Nameplate

66

60

30

24

66

61

58

35

33

32

31

26

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

8 (10mm2)

8 (10mm2)

10 (6mm2)

10 (6mm2)

8 (10mm2)

8 (10mm2)

8 (10mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

Fuse

(Super Lag)

or Breaker

Size

100

90

50

40

100

90

90

60

50

50

50

40

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes

4 (25 mm2)

4 (25 mm2)

10 (6mm2)

10 (6mm2)

4 (25 mm2)

4 (25 mm2)

4 (25 mm2)

8 (10mm2)

8 (10mm2)

8 (10mm2)

10 (6mm2)

10 (6mm2)

1Also called “inverse time” or “thermal/magnetic” circuit breakers; circuitbreakers which have a delay in tripping action that decreases as the magni-tude of the current increases.

A-3INSTALLATION

CV-400-I

A-3

FIELD INSTALLED OPTIONS

For installation of compatible field installed options(see the ACCESSORIES section of this manual andrefer to the instructions included with those options.

REQUIRED EQUIPMENT-CONTROLCABLE CONNECTIONS

Follow the instructions below which are appropriatefor the wire feeder that will be used.

LN-7 to CV-400-I

a) Turn the CV-400-I Power switch to the "OFF"position.

b) Connect the LN-7 control cable to the wire feederreceptacle on the CV-400-I.

c) See OUTPUT CONNECTIONS for connection ofwork and electrode cables.

LN-25 to CV-400-I


b) Plug a K484 jumper plug into the CV-400-I wirefeeder receptacle.


The output terminals are energized at all times whenthe K484 is plugged in.------------------------------------------------------------------------

LN-742 to CV-400-I


b) Connect the LN-742 control cable to the wirefeeder receptacle on the CV-400-I.


Connection of Remote Control (K857)

NOTE: The K864 Remote Control Adapter is requiredto install the K857.

Plug the K864 Remote Control Adapter into the powersource's 14-pin receptacle. Plug the K857 RemoteControl into the 6-pin receptacle of the K864 adapter.If possible, tape the Remote cable to the heavy outputleads, so they can protect the smaller Remote cablefrom damage and abuse.

OUTPUT CONNECTIONS

Output cables must have Magnum Twist-Mate™ plugsfor connection to the CV-400-I. Order K852-95 forconnecting 2/0-3/0 (70-95 mm2) cables. Refer toS18737 for instructions on installing these plugs.

Use the shortest possible cable lengths. See TableA.1 for recommended cable sizes based on length.

Connect the positive output lead to the terminalmarked "+". The negative output lead can be hookedto either the low inductance terminal (marked "

") or the high inductance terminal (marked" ").

WARNING

TABLE A.1Cable Sizes for Combined Lengths of Copper

Electrode and Work Cable

Machine SizeLengths up to

150 ft 150 to 200 ft

300 A 100%(400 A 60%) 2/0 (70mm2) 3/0 (95mm2)

A-4INSTALLATION

CV-400-I

A-4

PARALLELING

The CV-400-I is not designed to be paralleled with anyother power source.

CONNECTION OF AUXILIARY EQUIPMENTTO THE WIRE FEEDER RECEPTACLE

Occasionally, it may be necessary to make connectionto the circuits present in the 14-pin wire feeder recep-tacle. These circuits, such as the auxiliary voltage,contactor, and remote control circuits, may beaccessed with a K867 Universal Adapter. Thisadapter plugs into the receptacle and provides theuser with short wire leads for connections. Refer tothe instructions provided with the K867, as well as thewiring diagram for the CV-400-I power source, fordetails on making those connections. For your conve-nience, wire feeder connection details are shown inthe DIAGRAM section.

NOTE: If you intend to use a standard Lincoln wirefeeder, order the appropriate input cable forthe specific feeder. It will make all of the con-trol and power connections between the CV-400-I and the wire feeder WITHOUT theneed for a K867 Universal Adapter.

B-1OPERATIONB-1

CV-400-I

ELECTRIC SHOCKcan kill.

• Do not touch electrically live partsor electrode with skin or wetclothing.

• Insulate yourself from work andground.

• Always wear dry insulating gloves.

FUMES AND GASEScan be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

WELDING SPARKScan cause fire orexplosion

• Keep flammable material away.

• Do not weld on containers thathave held combustibles.

ARC RAYScan burn.

• Wear eye, ear and bodyprotection.

OPERATING INSTRUCTIONS

Read and understand this entire section before oper-ating the machine.

GENERAL WARNINGS

SAFETY PRECAUTIONS

Observe additional Safety Guidelines detailedthroughout this manual.

WARNING

B-2OPERATIONB-2

When using a CV-400-I power source with wire feeders,there will be a small spark if the electrode contacts the workor ground within several seconds after releasing the trigger.

When used with some wire feeders with the electrical triggerinterlock in the ON position, the arc might restart if the electrodetouches the work or ground during these several seconds.------------------------------------------------------------------------

GENERAL DESCRIPTIONThe CV 400-I is a constant voltage DC power sourcedesigned for the GMAW process with limited FCAW capabil-ity as well. It features an international rating of 400 amps,36 volts, at 60% duty cycle. It also has the capacity to runat 300 amps, 32 volts, 100% duty cycle.

The CV 400-I is available as a European model with 42 VACauxiliary power only, or as an export model with both 42 VACand 115 VAC auxiliary power. No options are available otherthan input voltage.

The European model of the CV 400-I features an all graphicnameplate and has an IEC 974-1 S Rating for use in envi-ronments with an increased hazard of electric shock.

RECOMMENDED PROCESSES ANDEQUIPMENT

The CV-400-I is capable of solid wire welding withinthe rated output capacity of the machine. It is alsocapable of welding with the following flux-cored wires:NR-152, NR-211, NS-3M, NR-203 Ni 1%, andOutershield® 70 and 71.

The CV-400-I (Export) is recommended for use withthe LN-7, LN-742 and LN-25 wire feeder models. TheCV-400-I (European) does not provide 115 VAC auxil-iary power for the LN-7 models.

OPERATIONAL FEATURES ANDCONTROLS

• Two inductance positions: operator can choose theoptimum output characteristics.

• Solid State Output Contactor: no noise, no movingparts to wear.

• Digital Voltmeter/Ammeter is standard.

• Power on/off switch.

• 42 VAC, 10 amp auxiliary power available for the wire feeder.

• Circuit breaker protected.

• 115 VAC, 5 amp auxiliary power available for the wirefeeder; circuit breaker protected. (Except Code 10182).

• 220 VAC, 2 amp Auxiliary power available for water cool-ers, using standard Continental European receptacle.

• Magnum Twist-Mate™ output receptacles.

• Single MS-type (14-pin) connection for wire feeder.

• Solid state controls, with line voltage compensation.

• Optional remote control capability.

DESIGN FEATURES

• "Clean" appearance and simple controls -- easy to operate.

• Electronic and thermostatic protection from overloads.

• Submersion dipping of assembled transformer, choke, andrectifier in special sealing/insulating material gives extra pro-tection against moisture and corrosive atmospheres.

• Microprocessor based Control PC Board has built-indiagnostic routines.

• Compact size, requires only 19" x 26" footprint.

• Modular construction for easy servicing.

• Recessed panels protect output studs and controls.Large safety margins and protective circuits protectrectifiers from transient voltages and high currents.

LIMITATIONS

The CV-400-I is intended only for use with the follow-ing FCAW electrodes: NR-152, NR-211, NR-203 Ni1%, NS-3M, Outershield 70 and 71. The machine hasbeen designed primarily for the GMAW process.

POWER SOURCE OPERATION

Be sure the CV-400-I is properly installed, and that allaccessories are properly hooked up before attemptingoperation.

DUTY CYCLE

300 Amps, 32 Volts at 100%400 Amps, 36 Volts at 60%

Duty Cycle is based on operation for a 10 minute period.

CV-400-I

CAUTION

B-3OPERATIONB-3

A. POWER SWITCH

- A two-position toggle switch.Controls theinput power to the CV-400-I.

B. VOLTAGE ADJUST

- Controls the CV-400-I output voltage.

C. THERMAL PROTECTION INDICATION LIGHT

- Indicates that the protection thermostat hasactivated. The digital meter will display "E10"when this occurs. When the light turns off,the machine will be capable of supplyingwelding output power again.

NOTE: Leaving the power switch in the "ON" posi-tion will result in the most rapid cooling.

D. VOLTS/AMPS SWITCH

- Selects either output current or arc voltageto be displayed on the digital meter.

E. DIGITAL VOLTMETER/AMMETER

- Displays the CV-400-I output current, or thearc voltage.

NOTE: Due to voltage drops in the welding cablesand at cable connection points, the actual arcvoltage may be lower than that displayed onthe voltmeter. Use welding cables of theproper capacity and make sure all connec-tions are tight to minimize this effect.

F. 42 VOLT CIRCUIT BREAKER

-Protects the 42 volt 41-42 circuit in the wirefeeder receptacle from overloads and shorts.If this circuit breaker opens, the CV-400-I willwork normally. However, any equipmentpowered by the 42 volt circuit will not work.

G. 115 VOLT CIRCUIT BREAKER

-Protects the 115 volt 31-32 circuit in the wirefeeder receptacle from overloads and shorts.If this circuit breaker opens, the CV-400-I willwork normally. However, any equipmentpowered by the 115 volt circuit will not work.

H. LOCAL/REMOTE SWITCH

-Determines whether the welding voltage iscontrolled at the CV-400-I, or controlledremotely by a remote output control (such asa K857).

CV-400-I

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the CV-400-I. Refer to Figures B.1, and B.2and corresponding explanations.

FIGURE B.1 - CONTROL PANEL

AB

CD

E

F G H JA. POWER SWITCH F. 42 VOLT CIRCUIT BREAKERB. VOLTAGE ADJUSTMENT G. 115 VOLT CIRCUIT BREAKERC. THERMAL PROTECTION INDICATION LIGHT H. LOCAL / REMOTE SWITCHD. VOLTS / AMPS SWITCH J. WIRE FEEDER VOLTMETER SWITCHE. DIGITAL VOLTMETER / AMMETER

B-4OPERATIONB-4

J. WIRE FEEDER VOLTMETER SWITCH

-This switch selects the polarity of the wirefeeder voltmeter, if so equipped. When weld-ing electrode positive (MIG, Outershield andsome Innershield processes) set the switchto "+".

-When welding electrode negative (mostInnershield electrodes) set the switch to "-".

-This switch has no effect on the weldingpolarity. In fact, if the wire feeder being useddoes not have a voltmeter, the setting of thisswitch has no effect.

CV-400-I

GRAPHIC SYMBOLS THAT APPEAR ONTHIS MACHINE OR IN THIS MANUAL

OFF

ON

ACPOWER

REMOTE OUTPUTVOLTAGE CONTROL

INDICATES WARNING INFORMATIONLOCATED ON RIGHT CASE SIDE

LOCAL OUTPUTVOLTAGE CONTROL

CIRCUITBREAKER

THERMAL PROTEC-TION INDICATOR

LIGHT

CLOCKWISE ROTA-TION INCREASES

VOLTAGE

AC AUXILIARYPOWER INPUT

WARNING

B-5OPERATIONB-5

CV-400-I

A., B., C. OUTPUT CONNECTORS

-Each connector is a Magnum Twist-Mate™,receptacle. Insert a mating Twist-Mate™plug, and twist clockwise to secure.

For GMAW processes, and most FCAWprocesses, the positive output connectiongoes to the wire feeder. One of the negativeoutput connections goes directly to the work.

A. POSITIVE OUTPUT CONNECTION.

B. LOW INDUCTANCE NEGATIVE CONNECTION.

-The low inductance connection is typicallyused for short arc welding of mild steel, par-ticularly on thin materials or when using CO2shielding gas.

C. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION.

-The high inductance connection is more suit-able for short arc welding heavier weldmentsor when using 75% Argon/25% CO2 shield-

ing gas. This connection produces a softerarc and a flatter bead with more wash-in thanthe low inductance connection. A spray typetransfer is possible with either connection.

D. WIRE FEEDER RECEPTACLE

-14-pin MS style receptacle for wire feeder.Provides connections for auxiliary power,contactor closure, remote output control, wirefeeder voltmeter sense lead, and ground.

OUTPUT PANEL CONNECTIONS

FIGURE B.2 - OUTPUT PANEL

A B CD

A. POSITIVE OUTPUT CONNECTION C. HIGH INDUCTANCE NEG. CONNECTIONB. LOW INDUCTANCE NEG. CONNECTION D. WIRE FEEDER RECEPTACLE

B-6OPERATIONB-6

CV-400-I

A. 220 VAC RECEPTACLEContinental European type, nonpolarized, ground-ed receptacle (also known as a "Schuko" type) forconnection of water coolers or other equipment.

B. CIRCUIT BREAKERProtects the 220 volt auxiliary circuit from over-

loads and shorts. If this breaker opens, the CV400-I will work normally; however, equipment pow-ered by the 220 volt receptacle will not work.

C. CABLE CLAMP FOR INPUT CABLES

CASE BACK CONNECTIONS

FIGURE B.3 - BACK PANEL

A

B

C

A. 220 VAC RECEPTACLE C. CABLE CLAMP FOR INPUT CABLESB. CIRCUIT BREAKER

B-7OPERATIONB-7

STARTING THE MACHINE

The power switch at the extreme right side of the con-trol panel energizes the CV-400-I.

ADJUSTING THE OUTPUT VOLTAGEUSING THE DIGITAL METER

The digital meters in the CV-400-I incorporate a voltage pre-set function. This allows the operator to set the desiredwelding voltage before striking an arc. The digital meterscan also display welding current.

To make use of the voltage preset function, the Volts/Ampsswitch must be in the "Volts" position. Turn the VoltageAdjust knob until the digital meter displays the desired weld-ing voltage. (See below if an external power source remotecontrol is installed.)

When an arc is struck, the digital meter displays the actualwelding voltage, as measured at the CV-400-I output termi-nals.

NOTE: The arc voltage at the electrode may be as much astwo volts different from the CV-400-I output terminalvoltage. This is due to voltage drops present in thewelding cables, cable connections, and weldinggun. To minimize these drops, use cables of ade-quate capacity, and make sure all connections areclean and tight. Because of these voltage drops,you may have to preset the CV-400-I for a slightlyhigher welding voltage than your procedure calls for.

To read welding current, set the Volts/Amps switch to the"Amps" position. The welding current will be displayedwhenever an arc is struck.

LOCAL/REMOTE SWITCH OPERATION

If voltage control is desired at the CV-400-I, theLocal/Remote switch must be in the "Local" position. TheVoltage Adjust on the front panel can be used to adjust theCV-400-I output. (The remote control, even if connected,will have no effect if the switch is in the "Local" position).

To use a remote control, such as the K857 (see INSTALLA-TION section), place the Local/Remote switch (see FigureB.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 theCV-400-I output.

AUXILIARY POWER

42 volt AC auxiliary power, as required for some wirefeeders, is available through the wire feeder recepta-cle. A 10 amp circuit breaker protects the 42 volt cir-cuit from overloads.

CV-400-I Export machines only can also supply 115volt AC auxiliary power through the wire feeder recep-tacle. A 5 amp circuit breaker protects the 115 voltcircuit from overloads.

The CV-400-I can supply 220 volt AC power at 2amps for powering water coolers or other equipment.This auxiliary power is available from the ContinentalEuropean type receptacle mounted on the case back.A 2 amp circuit breaker, located next to the recepta-cle, protects this auxiliary from overloads.

NOTE: Do not use circuits 2 or 4 for control of auxil-iary loads. (The 2-4 circuit is isolated from the31-32 and 41-42 circuits.)

Note that some types of equipment, especially pumpsand large motors, have starting currents which aresignificantly higher than their running current. Thesehigher starting currents may cause the circuit breakerto open. If this situation occurs, the user should refrainfrom using the CV-400-I auxiliary power for that equip-ment.___________________________________________

OVERLOAD PROTECTION

This welder has thermostatic protection from exces-sive duty cycles, overloads, loss of cooling, and highambient temperatures. When the welder is subjectedto an overload or loss of cooling, a thermostat willopen. This condition will be indicated by the illumina-tion of the yellow Thermostatic Protection Light on thecase front (see Figure B.1).The fan will continue to runto cool the power source. No welding is possible untilthe machine is allowed to cool and the ThermostaticProtection Light goes out.

CV-400-I

CAUTION

C-1ACCESSORIESC-1

FACTORY INSTALLEDOPTIONS/ACCESSORIES

There are no factory installed options/accessories onthe CV-400-I.

FIELD INSTALLED OPTIONS

REMOTE VOLTAGE CONTROL (K857)

The K857 consists of a control box with 25 feet (7.6m) of four conductor cable. Installation of a K857Remote Voltage Control in the CV-400-I requires aK864 Remote Control Adapter. Refer to the instruc-tions provided with the K857 for hookup to the CV-400-I. When properly connected, and with the CV-400-I Local-Remote Switch in the "Remote" position,the K857 functions the same as the CV-400-I VoltageAdjust control, enabling minimum to maximum outputvoltage adjustment of the CV-400-I.

UNDERCARRIAGE (K835)

Includes front casters, a handle, a bracket, and a rearwheeled platform that is capable of carrying one gascylinder. The CV-400-I lifting eye is not functional withthe K835 undercarriage installed.

TWO-CYLINDER UNDERCARRIAGE (K874)

Platform type undercarriage that can accommodateeither one or two gas bottles, or one gas bottle and aMagnum water cooler. The CV-400-I lifting eye is notfunctional when the K874 undercarriage is installed.

WIRE FEEDER SWIVEL MOUNT (K178-1)

Allows an LN-7 or LN-742 to be securely mounted onthe roof of a CV-400-I.

UNIVERSAL ADAPTER (K867)

Provides a means of connecting auxiliary equipmentto the wire feeder receptacle on the CV-400-I powersource. Consists of a 14-pin MS-type (Amphenol)plug with 8 inch (0.2 meter) long flex leads, one foreach circuit present in the wire feeder receptacle. Notrequired when using a standard wire feeder inputcable, such as a K480, with a Lincoln wire feeder.

COMPATIBLE LINCOLN EQUIPMENT

The CV-400-I is intended for use with the LN-7, LN-742, and LN-25 wire feed units. Use the Cables / Kitslisted below to make connection easily:

LN-7 / LN-7GMA* Requires K480 Input Cable

LN-25 Requires K484 Jumper Plug Kit

LN-25 w/K444-1 Requires K864 Remote ControlRemote Voltage Adapter and K484 Jumper PlugControl Kit Kit

LN-742 / LN-742H Requires K591 Input Cable

* European model CV-400-I does not provide 115 VAC auxiliary power for LN-7models.

CV-400-I

D-1MAINTENANCED-1

SAFETY PRECAUTIONS

GENERAL MAINTENANCE

1. The fan motor has sealed bearings which requireno service.

2. In extremely dusty locations, dirt may clog the airchannels causing the welder to run hot with prema-ture tripping of thermal protection. Blow out thewelder with low pressure air at regular intervals toeliminate excessive dirt and dust build-up on inter-nal parts.

MACHINE AND CIRCUIT PROTECTION

The CV-400-I Control PC Board has built-in diagnosticroutines to alert the operator when trouble exists.When a trouble condition occurs, the CV-400-I meterwill display an error code, in the form "EXX", where"XX" refers to a specif ic error. See TROU-BLESHOOTING section for an explanation of the errorcodes.

The power source is thermostatically protectedagainst overload or insufficient cooling. If the machineis overloaded, the thermostat will open, thermal pro-tection indicator light will turn on, and the output willbe zero. The fan will continue to run and auxiliarypower will still be available. The thermostat willremain open until the machine cools, at which time itwill close and the output will again be available.

The CV-400-I is electronically protected against over-loads and accidental short circuits. The overload pro-tection circuit automatically reduces the output currentto a safe value when an overload is detected. If thecircuitry senses a short circuit, it will shut off the CV-400-I output. The short circuit protection circuit canbe reset by turning the CV-400-I Power switch OFFfor at least 10 seconds. Remove the short beforeturning the Power switch ON again.

CV-400-I

ELECTRIC SHOCK can kill.

• Only qualified personnel shouldperform this maintenance.

• Turn the input power OFF at thedisconnect switch or fuse boxbefore working on thisequipment.

• Do not touch electrically hot parts.

WARNING

E-1TROUBLESHOOTINGE-1

CV-400-I

This Troubleshooting Guide is provided tohelp you locate and remedy possible prob-lems with machine setup or operation.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM(SYMPTOMS)”. This column describes pos-sible symptoms that the machine mayexhibit. Find the listing that best describesthe symptom that the machine is exhibiting.

Symptoms are grouped into three main cat-egories: output problems, function prob-lems, welding problems.

Step 2. PERFORM EXTERNAL TESTS.The second column labeled “POSSIBLEAREAS OF MISADJUSTMENT(S)” lists theobvious external possibilities that may con-tribute to the machine symptom. Performthese tests/checks in the order listed. Ingeneral, these tests can 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 LocalAuthorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoidElectrical Shock, please observe all safety notes and precautions detailed throughout this manual.__________________________________________________________________________

WARNING

If for any reason you do not understand the test procedures or are unable to performthe tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRICFIELD SERVICE FACILITY for assistance before you proceed._____________________________________________________________________

CAUTION


CV-400-I

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

ERRORCODE

TROUBLE REMEDY

E00

E10

E20

E30

E40

E50

E60

1. Output short circuited.

2. May be encountered whilestarting or welding with 1/16" alu-minum wire.

Thermostat circuit has opened.

Memory error.

1. Voltage Adjust potentiometer notconnected.

2. Remote Control not functioningcorrectly.

Input line voltage too low.

Input line voltage too high.

Overload condition.

1. Turn power off. Remove short circuit.

2. a) Turn power off to clear error. Use recommendedwfs, voltage settings and angle of approach of wireto work.

b) If problem still persists, call Local LincolnAuthorized Field Service Facility.

Allow machine to cool. Be sure to provide adequateventilation for machine.

See PC Board Troubleshooting Procedure.

1. Check wiring between Voltage Adjust and theControl PC Board.

2. See Options Troubleshooting Guide.

Turn power off. Insure machine input voltage is withinspecifications. Turn power back on.

Turn power off. Insure machine input voltage is withinspecifications. Turn power back on.

Reduce load on machine.

BUILT-IN DIAGNOSTIC ROUTINES AND ERROR CODES

The CV-400-I Meter PC Board displays error codes when certain trouble conditions exist. The error codes, trou-ble conditions, and possible remedies are listed below.

If, after attempting the remedies listed above, the error condition still exists, the problem may be with the wiring inthe following areas: the shunt (leads 218 and 219), or voltage feedback (leads 213B, 214B and 224B).


CV-400-I



CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)

POSSIBLE AREAS OFMISADJUSTMENTS(S)

RECOMMENDEDCOURSE OF ACTION

Machine has no output.

Machine has minimum output and nocontrol.

Machine has low output and no con-trol.

1. Secondary contactor circuit (2and 4 wire feeder receptacle) notworking.

2. Electrode or work lead loose orbroken.

3. Defective PC Board.

4. Protective circuits operating dueto output short circuit.

5. If using an LN-25, K484 jumperplug kit not making connectionbetween 2 & 4 in wire feederreceptacle.

6. If welding with 1/16" aluminumwire and machine is flashing E00.

1. Voltage Control misconnected.

1. Open in feedback circuitry.

2. Faulty PC Board.

3. Voltage Adjust potentiometercircuit open (lead 75).

1. Check 2 and 4 circuit wiring.

2. Repair connection.

3. See PC Board TroubleshootingProcedure.

4. Turn power off. Remove output shortcircuit.

5. Check for continuity between pins C& D in the K484.

6. a) Turn power off to clear error. Userecommended wfs, voltage set-tings and angle of approach ofwire to work.

b) If problem still persists, call Local LincolnAuthorized Field Service Facility.

1. Voltage Control wiring.

1. Check wiring and control and PCboard wiring harness plugs.


3. Check and replace potentiometer iffaulty. Check wiring of lead #75.

MACHINE TROUBLESHOOTING GUIDENot all trouble conditions can be recognized by the PC board, and displayed as error codes. The following guidecovers most other trouble conditions.


CV-400-I



CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)



Thermal Protection Indicator light ison.

Machine does not have maximumoutput

Machine will not shut off.

Variable or sluggish welding arc.

Digital meters do not light- or -

Digital meter display is incorrect.

1. Thermostat circuit has opened.

2. Faulty Control PC Board.


2. Voltage Adjust potentiometerdefective.

3. Voltage Adjust potentiometerleads open.

1. Defective power switch.

1. Poor work or electrodeconnection.

2. Welding leads too small.

3. Welding current or voltagetoo low.

4. Defective SCR bridge.

1. Faulty Meter PC board.


1. Allow machine to cool. Be sure toprovide adequate ventilation formachine.



2. Check and replace if faulty.

3. Check and repair broken leads.

1. Replace.

1. Check and clean all connections.

2. Check table in this manual.

3. Check procedures for recommendedsettings.

4. Check and replace if defective.




CV-400-I



CAUTION

PROBLEMS

PROBLEMS(SYMPTOMS)



Output Control not functioning on themachine.

Poor arc striking with semiautomaticwire feeders.

Poor arc characteristics

1. Local/Remote switch is inthe "Remote" position.

2. Faulty Voltage Adjustpotentiometer.

3. Leads or connections open incontrol circuit.

4. Malfunctioning Remote Control.

5. Faulty Control PC board.

1. Poor work connection.

2. Improper procedures.

3. Wire feed acceleration too fast ortoo slow.

4. Defective PC Board.

1. Control PC Board defective.

1. Move switch toggle to the "Local"position.

2. Check and replace if found faulty.

3. Check lead continuity and connec-tions for an open and repair if neces-sary.

4. See "Options Troubleshooting".


1. Work connection must be adequatefor application.

2. Adjust procedures for improved start-ing.

3. Adjust wire feeder acceleration set-ting, if provided.




CV-400-I


CAUTION


PROBLEMS

PROBLEMS(SYMPTOMS)



Output control not functioning onRemote Control.

Voltage Adjust not functioning on themachine.

1. Local/Remote switch in wrongposition.

2. Faulty Local/Remote switch.

3. Faulty Remote Control poten-tiometer.

4. Leads or connections open incontrol circuit.

5. Faulty Control PC board.

1. Local/Remote switch in thewrong position.

2. Faulty Local/Remote switch.

3. Faulty Voltage Adjustpotentiometer.

1. Place switch in "Remote".



4. Check all leads and connections,internal or remote, for continuity;repair if necessary.


1. Place switch in "Local" position.



OPTIONS TROUBLESHOOTING GUIDEK857 (or other) Remote Output Control


CV-400-I


CAUTION

Procedure for Replacing PC Boards

Before replacing a PC board which is suspected ofbeing defective, visually inspect the PC board in ques-tion for any electrical or mechanical damage to any ofits components and conductors on the back of theboard.

a. If there is no visible damage to the PC board,install a new one and see if this remedies the prob-lem. If the problem is remedied, reinstall the oldPC board to see if the problem still exists. If itdoes no longer exist with old PC board:

1. Check the PC board harness connector pins forcorrosion, contamination, or looseness.

2. Check leads in the plug harness for loose orintermittent connection.

b. If PC board is visibly damaged electrically, beforepossibly subjecting the new PC board to the samecause of failure, check for possible shorts, opens,or grounds caused by:

1. Frayed or pinched lead insulation.

2. Poor lead termination, such as a poor contactor a short to adjacent connection or surface.

3. Shorted or open motor leads, or other externalleads.

4. Foreign matter or interference behind the PCboards.

c. If PC board is visibly damaged mechanically,inspect for cause, then remedy before installing areplacement PC board.

If there is damage to the PC board or if replacingPC board corrects problem, return it to the localLincoln Electric Field Service Shop.

ELECTRIC SHOCK can kill.• Have a qualified individual install and

service this equipment.• Turn the power source input power off

at the disconnect switch before work-ing on this equipment.

• Do not touch electrically hot parts.---------------------------------------------------------------------

WARNING

PC BOARD TROUBLESHOOTINGPROCEDURES

CONTROL PC BOARD

The Control PC Board controls all machine functionsincluding the thermal protection indicator light and theMeter PC Board. Most problems, if not caused byfaulty wiring machine misuse, will stem from a faultyControl PC Board.

Perform the following diagnostic procedure beforereplacing the Control PC Board.

1. Turn off the input power at the fuse box.

2. Check for loose connections in the PC Boardplugs, particularly J3.

3. Disconnect the J3 plug from the Control PC Board.Measure the resistance between the following wireterminals in the plug:

A) Between wire #200 and wire #201.

B) Between wire #202 and wire #203.

Both of these resistances should be less than 1 ohm.

If these resistances are not less than 1 ohm, check thewiring back to the main transformer.

If these voltages are less than 1 ohm, refer to"Procedure for Replacing PC Boards."

METER PC BOARD

When the Meter PC Board malfunctions, first determineif the rest of the machine functions correctly. If so, thenthe problem is in either the harness between the meterand control boards, or in the meter board itself. Referto "Procedure for Replacing PC Boards". As a lastresort, the Control PC Board may have to be replaced.


CV-400-I


CAUTION

OUTPUT VOLTAGE

The open circuit voltage of the machine should be 10to 43 volts. If any other condition exists, refer to theTroubleshooting Guide.

FAULT PROTECTION OPERATION

The overload protection circuit on the PC Board willcause the CV-400-I meter to display "E60". This pro-tection circuit will reset itself automatically. The shortcircuit protection circuit will cause the meter to display"E00". The CV-400-I power switch must be turned"OFF" and then "ON" to return the machine to normaloutput.

CHECKING SNUBBER CIRCUIT

In case of an SCR malfunction or failure, the snubberassembly should be checked. Disconnect the inputpower to the CV-400-I at the fuse box and remove theright side of the machine.

1.Visually inspect the snubber PC Board assembly(located below the Control PC board on the case frontfor overheated components or damaged compo-nents).

OPTIONAL K857 REMOTE CONTROLCHECK

Disconnect the remote output control and connect an ohm-meter between pins C and B and rotate the rheostat in theremote control. The resistance reading should go from zeroto 10K ohms. Repeat with ohmmeter across A and B withthe same results. Connect ohmmeter across A and C. Thereading should be 10K ohms. A lower reading will indicate ashorted or partially shorted rheostat. A very high readingwill indicate an open rheostat. In either of the last twocases, replace the rheostat.

F-1DIAGRAMSF-1

CV-400-I

CONN

ECTO

R CA

VITY

NUM

BERI

NG S

EQUE

NCE

(CO

MPO

NENT

SID

E O

F P.

C. B

OAR

D)

ELEC

TRIC

AL S

YMB

OLS

P

ER E

1537

+ -

L1

SEC

ON

DAR

YTH

ERM

OST

AT

222

223

224

D4

C1

C2

C3 C4

+ + + +

R1

SCR

2

D2

D5

222

204A

204D

CO

NTR

OL

P. C

. BO

ARD

221

6 PI

N4

PIN

8 PI

N

SNU

BB

ER/B

YPAS

SP.

C. B

OAR

D

224

224A

224A

10A

CIR

CU

ITB

REA

KER

CB

1

L1 C

HO

KE

2 42V

12V

12V

-

204C

204D

204C

277

276

275

BAJC D

213

214

213

214

206

207

211

212

31 32

2 4

10 P

IN

S2MLNGFEH

VOLT

MET

ER

CUST

OMER

CONN

ECTI

ONS

115

VAC

42 V

AC

GROU

ND

WIR

EFE

EDER

RECE

PTAC

LE

205

WIR

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2534166154738

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C

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ING

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gra

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r re

fere

nce

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ay n

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l mac

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vere

d b

y th

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anua

l. T

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pec

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m f

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eth

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achi

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ne o

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m is

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rite

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vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

uip

men

t co

de

num

ber

..

F-2DIAGRAMSF-2

CV-400-I

CONN

ECTO

R CA

VITY

NUM

BERI

NG S

EQUE

NCE

(CO

MPO

NENT

SID

E O

F P.

C. B

OAR

D)

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TRIC

AL S

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1537

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AT

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223

224

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+ + + +

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NTR

OL

P. C

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ARD

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8 PI

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V 4

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NO

TE

: T

his

dia

gra

m is

fo

r re

fere

nce

onl

y.

It m

ay n

ot

be

accu

rate

fo

r al

l mac

hine

s co

vere

d b

y th

is m

anua

l. T

he s

pec

ific

dia

gra

m f

or

a p

artic

ular

co

de

is p

aste

d in

sid

eth

e m

achi

ne o

n o

ne o

f th

e en

clo

sure

pan

els.

If

the

dia

gra

m is

ille

gib

le, w

rite

to

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Ser

vice

Dep

artm

ent

for

a re

pla

cem

ent.

Giv

e th

e eq

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men

t co

de

num

ber

..

F-3DIAGRAMSF-3

CV-400-I

CV POWER SOURCE TO AN LN-7 AND K857

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

using

the

disc

onne

ct s

witc

h at

the

fuse

box

WAR

NING

Turn

off

input

pow

er to

the

Weld

ing P

ower

Sou

rce

Befo

re c

onne

cting

the

wire

feed

er.

ELEC

TRIC

SHO

CK

CAN

KIL

L

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

AND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.N

.B.

DIA

GR

AM S

HO

WS

ELEC

TRO

DE

POSI

TIVE

. TO

CH

ANG

E PO

LAR

ITY,

TU

RN

PO

WER

"O

FF",

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

EC

V/C

V-I

K48

0 IN

PUT

CAB

LE

LN-7

/LN

-7G

MA

WIR

EFE

EDER

REM

OTE

CO

NTR

OL

OPT

ION

AL K

857

TO W

OR

K

ASSE

MB

LY

OPT

ION

AL K

864

REM

OTE

CO

NTR

OL

ADAP

TER

N.C

.

N.C

. U

SE O

F TH

E K

857

REM

OTE

CO

NTR

OL

REQ

UIR

ES T

HE

INST

ALLA

TIO

N O

F A

K86

4 R

EMO

TEC

ON

TRO

L AD

APTE

R T

O T

HE

14 P

IN A

MPH

ENO

L O

F TH

E PO

WER

SO

UR

CE.

6-1

8-93

S20

662

F-4DIAGRAMSF-4

CV-400-I

CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

AND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.

N.C

. IN

SULA

TE E

ACH

UN

USE

D L

EAD

IND

IVID

UAL

LY.

N.C

.

768281

SPAR

E2 4 41 42 31 32 GN

D21 77 75

RE

MO

TE O

UTP

UT

CO

NTR

OLN

.D.

2 4

10K

MIN

.

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

using

the

disc

onne

ct s

witc

h at

the

fuse

box

WAR

NING

Turn

off

input

pow

er to

the

Weld

ing P

ower

Sou

rce

Befo

re c

onne

cting

the

wire

feed

er.

ELEC

TRIC

SHO

CK

CAN

KIL

L

6-1

8-93

NOT

USED

ON

CV/C

V-I P

OW

ER S

OUR

CES

42 V

AC

115

VA

CN

.E.

POW

ER S

OUR

CE F

RAM

E CO

NNEC

TIO

NW

IRE

FEED

ER V

OLT

MET

ER C

ONN

ECTI

ON

CONN

ECTS

TO

(WO

RK T

ERM

INAL

) OF

POW

ER S

OUR

CE

CONN

ECT

TOG

ETHE

R FO

R W

ELDI

NG O

UTPU

T

N.F

.

N.B

. D

IAG

RAM

SH

OW

S EL

ECTR

OD

E PO

SITI

VE.

TO C

HAN

GE

POLA

RIT

Y, T

UR

N P

OW

ER "

OFF

",

N.D

. FO

R W

IRE

FEED

ERS

THAT

RET

UR

N A

SIG

NAL

FO

R W

ELD

ING

OU

TPU

T, U

SE IS

OLA

TIO

N

REL

AY T

O C

LOSE

LEA

DS

2 &

4.TO K

867

N.E

. R

EFER

TO

PO

WER

SO

UR

CE

INST

RU

CTI

ON

MAN

UAL

FO

R M

AXIM

UM

AU

XILI

ARY

CU

RR

ENT

DR

AW.

TO WIR

EFE

EDER

K86

7 U

NIV

ERSA

LAD

APTE

R P

LUG

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

EC

V/C

V-I TO

WO

RK

ELEC

TRO

DE

CAB

LE

{

R

EVER

SE E

LEC

TRO

DE

AND

WO

RK

CAB

LES

AT P

OW

ER S

OU

RC

E.

N.F

. NO

T PR

ESEN

T O

N A

LL M

ACH

INES

N.F

.

S206

58

F-5DIAGRAMSF-5

CV-400-I

CV POWER SOURCE TO A K867 / K775 / LN-7

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

AND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.

N.C

. IN

SULA

TE E

ACH

UN

USE

D L

EAD

IND

IVID

UAL

LY.

SPAR

E82 81 42 41 31 32 2 4 21 G

ND

75 76 77

31 32 2 4 21 GN

D

N.C

.

K29

1 O

R K

404

INPU

T C

ABLE

K77

5 O

PTIO

NAL

REM

OTE

CO

NTR

OL

K86

7 U

NIV

ERSA

LAD

APTE

R P

LUG

75 76 77

GR

EEN

N.D

.

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

using

the

disc

onne

ct s

witc

h at

the

fuse

box

WAR

NING

Turn

off

input

pow

er to

the

Weld

ing P

ower

Sou

rce

Befo

re c

onne

cting

the

wire

feed

er.

ELEC

TRIC

SHO

CK

CAN

KIL

L

LN-7

WIR

EFE

EDER

N.D

. SP

LIC

E LE

ADS

AND

INSU

LATE

.

N.B

. D

IAG

RAM

SH

OW

S EL

ECTR

OD

E PO

SITI

VE.

TO C

HAN

GE

POLA

RIT

Y, T

UR

N P

OW

ER "

OFF

",

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

EC

V/C

V-I

TO W

OR

K

R

EVER

SE E

LEC

TRO

DE

AND

WO

RK

CAB

LES

AT P

OW

ER S

OU

RC

E.

6-1

8-93

S206

59

F-6DIAGRAMSF-6

CV-400-I

CV POWER SOURCE TO AN LN-25

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

using

the

disc

onne

ct s

witc

h at

the

fuse

box

WAR

NING

Turn

off

input

pow

er to

the

Weld

ing P

ower

Sou

rce

Befo

re c

onne

cting

the

wire

feed

er.

ELEC

TRIC

SHO

CK

CAN

KIL

L

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

AND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.N

.B.

DIA

GR

AM S

HO

WS

ELEC

TRO

DE

POSI

TIVE

. TO

CH

ANG

E PO

LAR

ITY,

TU

RN

PO

WER

"O

FF",

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

EC

V/C

V-I

OPT

ION

AL K

857

TO W

OR

K

LN-2

5W

IRE

FEED

ER

REM

OTE

CO

NTR

OL

OPT

ION

ALK

484

JUM

PER

PLU

G

R

EVER

SE E

LEC

TRO

DE

AND

WO

RK

CAB

LES

AT P

OW

ER S

OU

RC

E.N

.C. U

SE O

F TH

E K

857

REM

OTE

CO

NTR

OL

REQ

UIR

ES IN

STAL

LATI

ON

OF

A K

864

REM

OTE

C

ON

TRO

L AD

APTE

R T

O T

HE

14 P

IN A

MPH

ENO

L O

F TH

E PO

WER

SO

UR

CE.

N.D

.N

.D.

N.C

.

OPT

ION

AL K

864

REM

OTE

CO

NTR

OL

ADAP

TER

N.D

. CO

NN

ECT

THE

K48

4 JU

MPE

R P

LUG

DIR

ECTL

Y TO

TH

E 14

PIN

AM

PHEN

OL

OF

THE

POW

ER S

OU

RC

E IF

NO

REM

OTE

CO

NTR

OL

IS U

SED

.IF

USI

NG

A K

857

REM

OTE

CO

NTR

OL,

CO

NN

ECT

THE

K48

4 JU

MPE

R P

LUG

TO

TH

E 14

PIN

AM

PHEN

OL

OF

THE

K86

4 R

EMO

TE C

ON

TRO

L AD

APTE

R.

TH

E PO

WER

SO

UR

CE

WEL

DIN

G T

ERM

INAL

S AR

E A

LWAY

S "H

OT"

WH

EN T

HE

K48

4 JU

MPE

R

6-1

8-93

S206

61

F-7DIAGRAMSF-7

CV-400-I

CV POWER SOURCE TO AN LN-25 / K444-1

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

using

the

disc

onne

ct s

witc

h at

the

fuse

box

WAR

NING

Turn

off

input

pow

er to

the

Weld

ing P

ower

Sou

rce

Befo

re c

onne

cting

the

wire

feed

er.

ELEC

TRIC

SHO

CK

CAN

KIL

L

N.A

. W

ELD

ING

CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

AND

DU

TY C

YCLE

OF

APPL

ICAT

ION

.N

.B.

DIA

GR

AM S

HO

WS

ELEC

TRO

DE

POSI

TIVE

. TO

CH

ANG

E PO

LAR

ITY,

TU

RN

PO

WER

"O

FF",

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

EC

V/C

V-I

TO W

OR

K

LN-2

5W

IRE

FEED

ER

OPT

ION

ALK

484

JUM

PER

PLU

G

OPT

ION

AL K

864

REM

OTE

CO

NTR

OL

ADAP

TER

WIT

H K

444-

1 O

PTIO

N

N.D

.N

.D.

N.C

.

N.C

. CO

NN

ECT

THE

K48

4 JU

MPE

R P

LUG

TO

TH

E 14

PIN

REC

EPTA

CLE

OF

THE

K86

4 R

EMO

TE C

ON

TRO

L AD

APTE

R. C

ON

NEC

T TH

E 6

PIN

PLU

G F

RO

M T

HE

LN-2

5 (W

ITH

K44

4-1

OPT

ION

) TO

TH

E 6

PIN

REC

EPTA

CLE

OF

THE

K86

4

N.D

. TH

E PO

WER

SO

UR

CE

TER

MIN

ALS

ARE

ALW

AYS

"H

OT"

WH

EN T

HE

K48

4 JU

MPE

RPL

UG

KIT

IS IN

STAL

LED

.

R

EVER

SE E

LEC

TRO

DE

AND

WO

RK

CAB

LES

AT P

OW

ER S

OU

RC

E, S

WIT

CH

LN

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POLA

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ITC

H.

REM

OTE

CO

NTR

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ADAP

TER

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ITC

H T

HE

POW

ER S

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E "L

OC

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CH

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REM

OTE

.

S2

0663

CV

/CV

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OW

ER

SO

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LN

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WIT

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44

4-1

OP

TIO

N C

ON

NE

CT

ION

DIA

GR

AM

6

-18-

93

F-8DIAGRAMSF-8

CV-400-I

LINCOLN POWER SOURCE TO AN LN-742

Only

quali

fied

pers

ons

shou

ld in

stall

, use

or

serv

ice th

is m

achin

e.

WAR

NING

ELEC

TRIC

SHO

CK

CAN

KIL

L

ELEC

TRO

DE

CAB

LE

-+

14 P

INAM

PHEN

OL

POW

ER S

OU

RC

ELI

NC

OLN

TO W

OR

K

LN-7

42W

IRE

FEED

ER

Powe

r Sou

rce

befo

re c

onne

cting

the

wire

feed

er.

Turn

off

(0) t

he p

ower

swi

tch

on th

e W

elding

AND

14-

PIN

CAB

LE P

LUG

, R

EAR

VIE

WAN

D 1

4-PI

N C

ABLE

PLU

G,

FRO

NT

VIEW

K=4

2

C=2

D=4

E=77

F=76

G=7

5

H=2

1I=41

K=4

2

I=41 H

=21

G=7

5

F=76

E=77

D=4

C=2

PIN C D E F G H I K

42412175767742

LEAD

42V

AC42

V AC

WO

RK

OU

TPU

T C

ON

TRO

LO

UTP

UT

CO

NTR

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OU

TPU

T C

ON

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IGG

ER C

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TRIG

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IT

(SEE

APP

RO

PRIA

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IRIN

G D

IAG

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FUN

CTI

ON

FUN

CTI

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S AR

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STED

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EFER

ENC

EO

NLY

AN

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ACH

MAY

OR

MAY

NO

T B

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ESEN

T IN

YO

UR

EQ

UIP

MEN

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14-S

OC

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X R

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FRO

NT

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14-S

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IEW

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PUT

CAB

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N.C

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NS

NO

T LI

STED

AR

E N

OT

CO

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ECTE

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ELD

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CAB

LE M

UST

BE

SIZE

D F

OR

CU

RR

ENT

A

ND

DU

TY C

YCLE

OF

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ICAT

ION

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DIA

GR

AM S

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DE

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ETER

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OPE

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USI

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K58

9-1,

REM

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CO

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SET

PO

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SO

UR

CE

CO

NTR

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SWIT

CH

T

O "

REM

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SITI

ON

.

N.D

.

1-2

8-94

S20

409

F-9DIAGRAMSF-9

CV-400-I

K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS

INST

ALLA

TIO

N IN

STR

UC

TIO

NS

THIS

CO

NN

ECTO

R IS

MEA

NT

TO B

E U

SED

WIT

H L

INC

OLN

PO

WER

SO

UR

CES

WH

ICH

HAV

E A

14-P

IN

TO A

NY

OF

THE

14 C

IRC

UIT

S PR

ESEN

T IN

TH

E W

IRE

FEED

ER R

ECEP

TAC

LE.

WIR

E FE

EDER

REC

EPTA

CLE

. IT

IS D

ESIG

NED

TO

ALL

OW

TH

E U

SER

TO

MAK

E C

ON

NEC

TIO

NS

CO

NSU

LT T

HE

WIR

ING

DIA

GR

AM O

F TH

E PO

WER

SO

UR

CE

AND

WIR

E FE

EDER

TH

IS A

DAP

TER

WIL

L B

E U

SED

WIT

H.

2.

CO

NSU

LT T

HE

APPR

OPR

IATE

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UIP

MEN

T W

IRIN

G D

IAG

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UN

IVER

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ADAP

TER

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DAR

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IGN

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AND

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NC

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WN

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NO

T B

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TED

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ENT

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ITS

INSI

DE

THE

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DER

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RIM

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LUG

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K=4

2

A=32 B

=GN

D

C=2

L=82

D=4

E=77

M=8

1F=

76

G=7

5

N=S

PAR

E

H=2

1I=41

J=31

K=4

2

J=31

I=41 H=2

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N=S

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E

G=7

5

F=76

M=8

1E=

77

D=4

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B=G

NDA=

32PI

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SPAR

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A B C D E F G H I J K L M N8182 4231412175767742GN

D32LE

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OD

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TRO

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STAN

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ON

24V

AC

42V

AC11

5V A

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V AC

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RK

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TPU

T C

ON

TRO

LO

UTP

UT

CO

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TPU

T C

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115V

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V AC

(31,

32)

, 42

V AC

(41,

42)

, 24

V AC

(SPA

RE)

AN

D T

RIG

GER

CIR

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IT (2

, 4)

1.

TUR

N T

HE

POW

ER S

WIT

CH

OF

THE

WEL

DIN

G P

OW

ER S

OU

RC

E O

FF B

EFO

RE

INST

ALLI

NG

TH

IS A

DAP

TER

TO

WIR

E FE

EDER

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(SEE

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RO

PRIA

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G D

IAG

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)TH

ESE

FUN

CTI

ON

S AR

E LI

STED

FO

RR

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NLY

AN

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ACH

MAY

OR

MAY

NO

T B

E PR

ESEN

T IN

YO

UR

EQ

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MEN

T.

NO

T AL

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S AR

E PR

ESEN

T IN

EVE

RY

POW

ER S

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RC

E, N

OR

AR

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EY R

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IRED

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R G

REA

TER

.

3-1

6-90

S193

86

F-10DIAGRAMSF-10

CV-400-I

TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS

TURN THE POWER SWITCH OF THE WELDING POWERSOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLESOR WHEN CONNECTING OR DISCONNECTING PLUGS TOWELDING POWER SOURCE.

1.

WELDING CABLE

BOOT

TRIM

Slide the copper tube into the brass plug.

Insert cable into copper tube.

COPPER TUBE

Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces afterthe plug is locked into the receptacle.

SET SCREW

BRASS PLUG

BOOT MARKING

2

2

50-70

70-95

CABLE SIZE

1/0-2/0

CABLE SKIN LENGTH

1 INCH (25.4mm)

2.

2/0-3/0

50-70

70-95

mm )

mm )

(

(

AMERICAN (EUROPEAN) RANGE

CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THEAPPROPRIATE CABLE SIZE PER TABLE BELOW; ANDSKIN CABLE JACKET TO LENGTH SPECIFIED:

1 INCH (25.4mm)35-50 2mm )( 35-50#2-#1

TWIST-MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS

9-20-91J

1.5 INCH (38.1mm)

must apply firm pressure against welding cable. The top of the

(70-95 size mayhave 2 setscrews)

SEEABOVE

Tighten set screw(s) to collapse copper tube. Screw(s)

brass plug after tightening.set screw(s) will be nearly flush or below the surface of the

7.

6.

5.

4.

3. Slide rubber boot onto cable end.

If necessary, trim cable end of boot at groove(s) to match cablediameter. Boot must fit tightly enough to seal around outside

different cable diameters without trimming. These boots do not

based lubricant will help to slide the boot over the cable.have grooves at the cable end. Soap or other non petroleum

diameter of cable. NOTE: Some boots are designed to accommodate

S18737

F-11DIAGRAMSF-11

CV-400-I

CONNECTION OF NON-LINCOLN WIRE FEEDERS

F-12DIAGRAMSF-12

CV-400-I

DIMENSION PRINT

5-1

8-90

J

N.A

.

N.A

.

N.A

.

N.A

.FO

UR

SLO

TS IN

BAS

E FO

R M

OU

NTI

NG

WEL

DER

DO

WN

USI

NG

5/1

6 SC

REW

S

1.68

N.B

.

N.B

. H

AND

LE C

ON

FIG

UR

ATIO

N O

N E

ARLI

ER M

OD

ELS.

20.0

5 (5

09)

19.6

5 (4

99)

19.2

0 (4

87)

41.5

8 (1

056)

26.0

0 (6

60)

3.61

(91)

12.6

0 (3

20)

(42.

7)

11.9

9 (3

04)

3.90

(99)

.28

(7.0

)

1.00

(25.

4)23

.62

(600

)

6.20

(157

)

30.9

5(7

86)

1.38

(35)

17.2

5 (4

38) (

CEN

TER

ED)

21.5

0 (5

46)

24.7

5(6

28)

M15

665

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WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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im501-a idealarc cv-400-i · 1.a. turn the engine off before troubleshooting and maintenance work...

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