Lincoln CV400 PDF

View Safety Info
SVM136-B
April, 2012
IDEALARC CV400, CV500-I

For use with machine code number:
10084 thru 10092, 10277, 10278, 11087 thru 11089,
11354 thru 11356, 11835 thru 11837
Return to Master TOC
View Safety Info

View Safety Info
Safety Depends on You
RETURNTOMAIN INDEX
Lincoln arc welding and cutting

equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DONOT 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.
View Safety Info
SERVICE MANUAL
Copyright Lincoln Global Inc.
World's Leader in Welding and Cutting Products

Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEBSITE: www.lincolnelectric.com
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
The engine exhaust from this product contains
are known to the State of California to cause canchemicals known to the State of California to cause
cer, birth defects, and other reproductive harm.
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 you
purchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work 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 before refueling to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine 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 and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
hot.
1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
ELECTRIC AND
MAGNETIC FIELDS
may 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, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them 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 and
work 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 as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.5. Do not work next to welding power source.
IDEALARC CV-400, CV-500I
SAFETY
ii
ELECTRIC SHOCK can kill.
ARC RAYS can burn.
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 bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.a.
Use a shield with the proper filter and cover

plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.b. Use suitable clothing made from durable flame-resistant

material to protect your skin and that of your helpers from
the arc rays.
In addition to the normal safety precautions, if welding

must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
Semiautomatic DC Constant Voltage (Wire) Welder.
DC Manual (Stick) Welder.
AC Welder with Reduced Voltage Control.
4.c. Protect other nearby personnel with suitable, non-flammable

screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
3.c. In semiautomatic or automatic wire welding, the electrode,

electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically hot.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should 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 and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
ii
3.h. Never simultaneously touch electrically hot parts of

electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES

can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized
steel.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturers instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employers safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
iii
WELDING and CUTTING

SPARKS can cause fire or
explosion.
6.a. Remove fire hazards from the welding area.If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjcent areas. Avoid welding near hydraulic
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 hazardous
situations. Refer to Safety in Welding and Cutting (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been cleaned. For information, purchase Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
iii
CYLINDER may explode

if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
Away from areas where they may be struck or subjected to
physical damage.
A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically hot parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
Precautions for Safe Handling of Compressed Gases in
Cylinders, available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing through
lifting chains, crane cables or other alternate circuits. This can
create fire hazards or overheat lifting chains or cables until
they fail.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturers
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturers recommendations.
6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B Standard for Fire Prevention
During Welding, Cutting and Other Hot Work, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
SAFETY
iv
iv
PRCAUTIONS DE SRET
6. Eloigner les matriaux inflammables ou les recouvrir afin de

prvenir tout risque dincendie d aux tincelles.
Pour votre propre protection lire et observer toutes les instructions

et les prcautions de sret specifiques qui parraissent dans ce
manuel aussi bien que les prcautions de sret gnrales suivantes:
7. Quand on ne soude pas, poser la pince une endroit isol de

la masse. Un court-circuit accidental peut provoquer un
chauffement et un risque dincendie.
Sret Pour Soudage A LArc

1. Protegez-vous contre la secousse lectrique:
a. Les circuits llectrode et la pice sont sous tension
quand la machine souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vtements mouills. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trs attention de bien sisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans
les positions assis ou couch pour lesquelles une grande
partie du corps peut tre en contact avec la masse.
c. Maintenir le porte-lectrode, la pince de masse, le cble de
soudage et la machine souder en bon et sr tat defonctionnement.
d.Ne jamais plonger le porte-lectrode dans leau pour le
refroidir.
e. Ne jamais toucher simultanment les parties sous tension
des porte-lectrodes connects deux machines souder
parce que la tension entre les deux pinces peut tre le total
de la tension vide des deux machines.
f. Si on utilise la machine souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-lectrode sapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le cble-lectrode autour de nimporte quelle partie du
corps.
8. Sassurer que la masse est connecte le plus prs possible de

la zone de travail quil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dautres endroits
loigns de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
cbles de grue, ou autres circuits. Cela peut provoquer des
risques dincendie ou dechauffement des chaines et des
cbles jusqu ce quils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particulirement important pour le soudage de tles
galvanises plombes, ou cadmies ou tout autre mtal qui
produit des fumes toxiques.
10. Ne pas souder en prsence de vapeurs de chlore provenant
doprations de dgraissage, nettoyage ou pistolage. La
chaleur ou les rayons de larc peuvent ragir avec les vapeurs
du solvant pour produire du phosgne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sret, voir
le code Code for safety in welding and cutting CSA Standard
W 117.2-1974.
PRCAUTIONS DE SRET POUR

LES MACHINES SOUDER
TRANSFORMATEUR ET
REDRESSEUR
3. Un coup darc peut tre plus svre quun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropri ainsi
quun verre blanc afin de se protger les yeux du rayonnement de larc et des projections quand on soude ou
quand on regarde larc.
b. Porter des vtements convenables afin de protger la peau
de soudeur et des aides contre le rayonnement de larc.
c. Protger lautre personnel travaillant proximit au
soudage laide dcrans appropris et non-inflammables.
4. Des gouttes de laitier en fusion sont mises de larc de
soudage. Se protger avec des vtements de protection libres
de lhuile, tels que les gants en cuir, chemise paisse, pantalons sans revers, et chaussures montantes.
1. Relier la terre le chassis du poste conformement au code de

llectricit et aux recommendations du fabricant. Le dispositif
de montage ou la piece souder doit tre branch une
bonne mise la terre.
2. Autant que possible, Iinstallation et lentretien du poste seront
effectus par un lectricien qualifi.
3. Avant de faires des travaux linterieur de poste, la debrancher linterrupteur la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sret leur place.
5. Toujours porter des lunettes de scurit dans la zone de

soudage. Utiliser des lunettes avec crans lateraux dans les
zones o lon pique le laitier.
SAFETY
Electromagnetic Compatibility (EMC)

Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturers
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
SAFETY
vi
Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturers recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturers recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturers recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applications. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.
vi
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURNTOMAIN INDEX
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-vi
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-236
A-1
TABLE OF CONTENTS - INSTALLATION SECTION
Installation.............................................................................................................................Section A
Technical Specifications ..............................................................................................................A-2
Safety Precautions ......................................................................................................................A-3
Location and Ventilation ..............................................................................................................A-3
Lifting ....................................................................................................................................A-3
Stacking ................................................................................................................................A-3
Tilting ....................................................................................................................................A-3
Electrical Input Connections........................................................................................................A-3
Ground Connection...............................................................................................................A-4
Input Power Supply Connections .........................................................................................A-4
Reconnect Procedure .................................................................................................................A-6
Output Connections ....................................................................................................................A-6
Connect Electrode and Work Leads to Output Terminals ....................................................A-6
Connect Wire Feeders..........................................................................................................A-9
Input Wire and Fuse Size .....................................................................................................A-5
A-1
INSTALLATION
Return to Section TOC
A-2
A-2
TECHNICAL SPECIFICATIONS - IDEALARC CV-400, CV-500-I

INPUT - THREE PHASE ONLY
Standard Voltage
Input Current at Rated Output
230/460 (60Hz)
77A/39A @ 400A 36V
220/380/440 (50Hz)
RATED OUTPUT
Duty Cycle
Welding Output
Volts at Rated Amps
100%
60%
50%
400
450
500
36*
38
40
OUTPUT
Current
Range
Voltage
Range
Maximum Open
Circuit Voltage
Auxiliary
Power
60 - 500 Amps
12 - 42 Volts
46 VDC
115 VAC, 10 Amps

42 VAC, 10 Amps
RECOMMENDED INPUT WIRE AND FUSE SIZES

Input Voltage/
Frequency
Volts/Hz
Input Amps
Rating on
Nameplate
Fuse
(Super Lag)
or Breaker
Size
230
460
77
39
125
60
Type 75 C
Copper Wire in
Conduit AWG
(IEC) Sizes
Type 75 C
Copper Ground
Wire in Conduit
AWG (IEC) Sizes
3 (27 mm2)
8 (8.4 mm2)
6 (13 mm2)
10 (5.3 mm2)
PHYSICAL DIMENSIONS
Height2
Width
Depth
Weight
27.5 in. (699 mm)
22.2 in. (565 mm)
32.0 in. (813 mm)
357 lbs. (162 kg)
* No added capacity over NEMA rated 36V at 400 amps.
INSTALLATION
A-3
Read this entire installation section before you

start installation.
SAFETY PRECAUTIONS
WARNING
Insulate yourself from the work

and ground.
Turn power switch off before connecting or disconnecting cables or connections.
IDEALARC CV-400s may be stacked three high. The

bottom machine must be on a stable, hard, level surface capable of supporting the weight of up to three
machines (1071 pounds/486 kilograms). Be sure that
the two holes in the top front corners of the bottom
machine line up with the holes in the base rails of the
machine above. Fasten the machines together with
5/16" bolts, lockwashers, and nuts through these
holes. The lift hook is positioned so that it fits without
interference under the base of the second machine.
Always connect grounding terminal to a proper electrical earth ground.
TILTING
Only qualified personnel should install, use, or service this equipment.
LOCATION AND VENTILATION
The IDEALARC CV-400 weighs 357 pounds (162 kilograms). A permanent lift hook is located at the top of
the machine, positioned at the center of gravity for stable lifting.
STACKING
Do not touch electrically live

parts such as output terminals or
internal wiring.
Place the IDEALARC CV-400 where clean, cooling air

can flow freely in through the front louvers and out
through the rear louvers. Keep dust, dirt, and other foreign materials that can be drawn into the machine to a
minimum. Failure to observe these precautions can
lead to excessive operating temperatures and nuisance shut-downs.
THE CV-400 carries an IP-21 environmental rating.
Locate indoors or shelter from falling water such as rain.
Place the machine on a secure, level surface. Any surfaces you place it on other than the ground must be
firm, non-skid, and structurally sound.
ELECTRICAL INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the input
power is as specified on the rating plate, located on the
case front control panel. See Figure A.1.
Input supply line entry is through a hole in the case rear
top panel. A removable door covers the input connection box, which contains the input contactor (CR1) and
reconnect panel assembly for multiple voltage connection. Input power is connected to the three line terminals on the input contactor. See Figure A.2.
LIFTING
WARNING
FALLING EQUIPMENT can cause injury.
Do not lift this machine using the lift

hook if it is equipped with a heavy
accessory such as a trailer or a gas
cylinder.
A-3
Lift only with equipment of adequate

lifting capacity.
Be sure the machine is stable when lifting.
Do not stack more than three high.
Do not stack the CV-400 on top of any other machine.
INSTALLATION
A-4
A-4
FIGURE A.1
RATING PLATE LOCATION
1. RATING PLATE
GROUND CONNECTION
INPUT SUPPLY CONNECTIONS
The frame of the welder must be grounded. An earth

grounding lead must be connected to the grounding
terminal, marked on the input box floor with the symbol
(See Figure A.2). Refer to Technical Specifications page for proper ground wire size.
Be sure the voltage, phase, and frequency of the input

power is the same as specified on the rating plate.
WARNING
Have a qualified electrician
install and service this equipment.
Turn the input power off at the
fuse box before working on this
equipment.
Do not touch electrically hot parts.
INSTALLATION
Fuse the input circuit with the super lag fuse recommended in the Technical Specifications at the beginning of this section or use delay type1 circuit breakers.
Choose an input and grounding wire size according to
local or national codes; also see the Technical
Specifications. Using fuses or circuit breakers smaller
than recommended may result in "nuisance" shut-offs
from welder inrush currents, even if you are not welding at high output currents.

A-5
INPUT WIRE AND FUSE SIZE
FIGURE A.2
REAR PANEL
A-5
Also called "inverse time" or "thermal/magnetic" circuit breakers.

These circuit breakers trip faster as the magnitude of the fault current increases.
FIGURE A.3
INPUT POWER SUPPLY CONNECTIONS
1.
2.
3.
4.
INPUT SUPPLY LINE ENTRY HOLE

INPUT CONTACTOR CR1
RECONNECT PANEL/JUMPER LINKS
GROUND TERMINAL
Have a qualified electrician connect the input power

leads to the L1, L2, and L3 terminals of the input contactor. Follow all national and local electrical codes.
Use a three-phase line. Install the reconnect panel
jumper links (see Figure A.3) for the proper input voltage. See the connection diagram located on the inside
cover of the access panel cover. Also refer to
Reconnect Procedure later in this section.
1. INPUT SUPPLY LINE

2. INPUT CONTACTOR
3. RECONNECT PANEL/JUMPER LINKS
INSTALLATION
A-6
RECONNECT PROCEDURE
OUTPUT CONNECTIONS
Multiple input voltage welders are shipped from the factory connected for the highest voltage listed on the
machine's rating plate. Before installing the welder, be
sure the reconnect panel is connected for the proper
voltage.
CONNECT ELECTRODE AND WORK

LEADS TO OUTPUT TERMINALS
Failure to follow these instructions can cause immediate failure of components in the welder.
To reconnect a multiple voltage machine to a different

voltage, remove input power and change the position
of the jumper links on the reconnect panel. Follow the
input connection diagram, located on the inside access
panel cover, appropriate for your machine's input voltage. This same connection diagram is shown in Figure
A.4 below.
A-6
The output (welding) cables are connected to the output terminals marked "+" and "-" . These 1/2" terminals
are located at the lower right and lower left corners of
the front panel. See Figure A.5.
See Table A.1 for recommended cable sizes for combined lengths of electrode and work cables.
FIGURE A.4
INPUT CONNECTION DIAGRAM FOR 230/460 VOLTS AC, 50/60 HZ
Do not operate with covers
removed
Disconnect input power before
servicing
Do not touch electrically live parts

Only qualified persons should install,
use or service this equipment
DUAL VOLTAGE MACHINE

INPUT SUPPLY CONNECTION DIAGRAM
IMPORTANT: CHANGE LINK POSITIONS AND PILOT TRANSFORMER CONNECTIONS.
NOTE: MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS
CONNECTION FOR HIGHEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK
LINES
INPUT
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
L3
W CR1
L2
V
CONTACTOR
L1
GND
2. DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT

LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS
TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
H3
H1
4. CONNECT TERMINAL MARKED

CODES.
H2
PILOT

TRANSF.
TO GROUND PER LOCAL AND NATIONAL ELECTRIC
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE
USE. SECURE THE REMAINING HEX NUTS IN PLACE.
CONNECTION FOR LOWEST RATING PLATE VOLTAGE, 50 OR 60 HZ.

LINK
1. TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX.
W CR1
L3
LINES
INPUT
L2
L1
GND
2. DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TAPE TO PROVIDE AT

LEAST 600 VOLT INSULATION.
3. CONNECT L1, L2 & L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS

TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN.
CONTACTOR
H2
H1
4. CONNECT TERMINAL MARKED

CODES.
H3
TO GROUND PER LOCAL AND NATIONAL ELECTRIC
5. MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS.
PILOT
TRANSF.
THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A.
A-7
INSTALLATION
FIGURE A.5
OUTPUT TERMINAL CONNECTIONS
1
A-7
1. NEGATIVE (-) WELDING CABLE CONNECTION

2. POSITIVE (+) WELDING CABLE CONNECTION
TABLE A.1 - CABLE SIZES FOR COMBINED LENGTH

OF ELECTRODE AND WORK CABLE
CABLE LENGTHS
400A
(100% DUTY
CYCLE)
500A
(50% DUTY
CYCLE)
UP TO 50 ft
(15 m)
3/0
85 mm2
2/0
67 mm2
50 to 100 ft
(15 to 30 m)
3/0
85 mm2
2/0
67 mm2
100 to 150 ft
(30 to 46 m)
3/0
85 mm2
3/0
85 mm2
150 to 200 ft
(46 to 61 m)
3/0
85 mm2
3/0
85 mm2
200 to 250 ft
(67 to 76 m)
4/0
107 mm2
4/0
107 mm2
MACHINE LOAD

Lincoln CV400 PDF

Uploaded by

Copyright:

Available Formats

Lincoln CV400 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Lincoln CV400 PDF

Uploaded by

Copyright:

Available Formats

View Safety Info

IDEALARC CV400, CV500-I

10084 thru 10092, 10277, 10278, 11087 thru 11089,

11354 thru 11356, 11835 thru 11837

Return to Master TOC

View Safety Info

Safety Depends on You

Return to Master TOC

Return to Master TOC

Lincoln arc welding and cutting

View Safety Info

Return to Master TOC

Copyright Lincoln Global Inc.

World's Leader in Welding and Cutting Products

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

1.h. To avoid scalding, do not remove the

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

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

IDEALARC CV-400, CV-500I

Return to Master TOC

Return to Master TOC

ELECTRIC SHOCK can kill.

ARC RAYS can burn.

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

Use a shield with the proper filter and cover

4.b. Use suitable clothing made from durable flame-resistant

In addition to the normal safety precautions, if welding

4.c. Protect other nearby personnel with suitable, non-flammable

3.c. In semiautomatic or automatic wire welding, the electrode,

Return to Master TOC

3.h. Never simultaneously touch electrically hot parts of

FUMES AND GASES

Return to Master TOC

IDEALARC CV-400, CV-500I

Return to Master TOC

WELDING and CUTTING

Return to Master TOC

6.c. When not welding, make certain no part of the electrode

CYLINDER may explode

Return to Master TOC

6.h. Also see item 1.c.

Return to Master TOC

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

IDEALARC CV-400, CV-500I

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

6. Eloigner les matriaux inflammables ou les recouvrir afin de

Pour votre propre protection lire et observer toutes les instructions

7. Quand on ne soude pas, poser la pince une endroit isol de

Sret Pour Soudage A LArc

8. Sassurer que la masse est connecte le plus prs possible de

PRCAUTIONS DE SRET POUR

1. Relier la terre le chassis du poste conformement au code de