Lincoln Electric Welder CV 250 User Manual

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IM505  
IDEALARC ®CV-250  
December, 1999  
For use with machine Code Numbers 10013, 10014  
Safety Depends on You  
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 thought-  
ful operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
Date of Purchase:  
Serial Number:  
Code Number:  
Model:  
Where Purchased:  
OPERATOR’S MANUAL  
• World's Leader in Welding and Cutting Products •  
• 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  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
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.  
kill.  
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.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.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.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
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 below Threshold Limit Values (TLV)  
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.  
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.  
5.b. 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.  
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.  
5.c. 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.  
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.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
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.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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 adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
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.  
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.  
7.c. Cylinders should be located:  
Away from areas where they may be struck or subjected to  
physical damage.  
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.  
•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.  
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).  
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.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
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.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
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 cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
Pour votre propre protection lire et observer toutes les instruc-  
tions et les précautions de sûreté specifiques qui parraissent  
dans ce manuel aussi bien que les précautions de sûreté  
générales suivantes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler 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 couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles 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 tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
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. Ne  
jamais enrouler le câble-électrode autour de n’importe quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude  
ou quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflamma-  
bles.  
2. Autant que possible, I’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection  
libres de l’huile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
Mar. ‘93  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found 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 information  
you have recorded above.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy 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:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
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TABLE OF CONTENTS  
vi  
Page  
Installation .......................................................................................................Section A  
Technical Specifications ........................................................................................A-1  
Select Suitable Location ........................................................................................A-2  
Input Connections..................................................................................................A-2  
Field Installed Options ...........................................................................................A-3  
Required Equipment - Control Cable Connections................................................A-3  
Output Connections...............................................................................................A-3  
Paralleling .............................................................................................................A-4  
Connection of Auxiliary Equipment to Wire Feeder Receptacle............................A-4  
Operation .........................................................................................................Section B  
Safety Precautions ................................................................................................B-1  
General Description...............................................................................................B-2  
Recommended Processes and Equipment ...........................................................B-2  
Operational Features and Controls........................................................................B-2  
Design Features ....................................................................................................B-2  
Limitations..............................................................................................................B-2  
Power Source Operation .......................................................................................B-2  
Duty Cycle .............................................................................................................B-2  
Controls and Settings ............................................................................................B-3  
Graphic Symbols ...................................................................................................B-4  
Output Panel Connections.....................................................................................B-5  
Starting the Machine..............................................................................................B-6  
Adjusting the Output Voltage using the Digital Meter............................................B-6  
Local/Remote Switch Operation ............................................................................B-6  
Auxiliary Power......................................................................................................B-6  
Overload Protection...............................................................................................B-6  
Accessories.....................................................................................................Section C  
Factory/Field Installed Options..............................................................................C-1  
Compatible Lincoln Equipment..............................................................................C-1  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
General Maintenance ............................................................................................D-1  
Machine and Circuit Protection..............................................................................D-1  
Troubleshooting..............................................................................................Section E  
Safety Precautions.................................................................................................E-1  
How to Use Troubleshooting Guide.......................................................................E-1  
Built-in Diagnostic Routines and Error Codes -Troubleshooting Guide.................E-2  
Machine -Troubleshooting Guide...........................................................................E-3  
Options -Troubleshooting Guide............................................................................E-6  
Procedure for Replacing PC Boards......................................................................E-7  
Control and Meter PC Board Troubleshooting Procedures ...................................E-7  
Output Voltage, Fault Protection, Snubber Circuit and K857 Remote Control Checks....................E-8  
Diagrams ..........................................................................................................Section F  
Parts Manual....................................................................................................Appendix  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS – IDEALARC CV-250  
INPUT - THREE PHASE ONLY  
Standard  
Voltage  
208/230/460/3/60  
Input Current at  
Rated Output  
Code  
Number  
10013  
100% Duty Cycle 56/51/26  
60% Duty Cycle 62/56/28  
230/460/575/3/60  
10014  
100% Duty Cycle 51/26/20  
60% Duty Cycle 56/28/22  
RATED OUTPUT  
Duty Cycle  
100% Duty Cycle  
NEMA Class I (100)  
60% Duty Cycle  
100% Duty Cycle  
Volts at Rated Amperes  
Amps  
30  
250  
32  
30  
300  
250  
OUTPUT  
Welding Current/Voltage Range  
(Continuous)  
Auxiliary Power  
Normal Open Circuit Voltage  
10-43  
42 Volts AC, 10 Amps  
30A/7V - 300A/32V  
DC  
MAX OCV: 50  
115 Volts AC, 5 Amps  
( Both Circuit Breaker Protected)  
MISC. INFORMATION  
Idle Current - Amps  
Efficiency at 100% Load  
Input kVA  
11/10/5  
72%  
60% Load - 22.3  
100% Load - 20.3  
Idle Power  
Power Factor at 100% Load  
800W  
.53  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
21.5 in.  
19.5 in.  
27.0 in.  
(Lift bail, add 3.12 in)  
300 lbs  
(137 kg)  
546 mm  
495 mm  
(Lift bail, add 80 mm)  
686 mm  
CV-250  
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A-2  
A-2  
INSTALLATION  
Read entire installation section before starting  
installation.  
INPUT CONNECTIONS  
Be sure the voltage, phase, and frequency of the input  
power is as specified on the welder nameplate.  
SAFETY PRECAUTIONS  
WARNING  
Gain access to the input reconnect panel by removing  
the right case side of the CV-250 (side nearest to the  
Power switch.)  
ELECTRIC SHOCK can kill.  
Only qualified personnel should  
perform this installation.  
Have a qualified electrician connect the input leads to  
L1, L2, and L3 of the input reconnect panel in accor-  
dance with the National Electrical Code, all local  
codes, and the connection diagram located on the  
inside of the right case side. Use a three phase line.  
• Turn the input power OFF at the discon-  
nect switch or fuse box before working on  
this equipment.  
• Turn the Power switch on the CV-250  
“OFF” before connecting or disconnect-  
ing output cables, wire feeder or remote  
connections, or other equipment.  
The frame of the welder must be grounded. A ground  
• Do not touch electrically hot parts.  
terminal marked with the symbol  
located on the  
• Always connect the Idealarc CV-250  
grounding terminal (located on the welder  
base near the reconnect panel) to a good  
electrical earth ground.  
base of the machine is provided for this purpose. See  
the National Electrical Code for details on proper  
grounding methods.  
Fuse the input circuit with the recommended super lag  
fuses. Choose an input and grounding wire size  
according to local codes or use the following table.  
SELECT SUITABLE LOCATION  
Place the welder where clean cooling air can freely  
circulate in through the side louvers and out through  
the rear louvers. Dirt, dust or any foreign material that  
can be drawn into the welder should be kept at a  
minimum. Failure to observe these precautions can  
result in excessive operating temperatures and  
nuisance shut-downs. Idealarc CV-250 power sources  
carry an IP23 enclosure rating. They are rated for use  
in damp, dirty environments subject to occasional  
falling water such as rain.  
1
"Delay type" circuit breakers may be used in place of  
fuses. Using fuses or circuit breakers smaller than  
recommended may result in "nuisance" tripping from  
welder inrush currents even if not welding at high cur-  
rents.  
RECOMMENDED INPUT WIRE AND FUSE SIZES  
Type 75°C  
Fuse  
Input  
Type 75°C  
Copper  
(Super Lag) Ampere Copper Wire in  
or Breaker Rating on Conduit AWG  
Input  
Voltage /  
Frequency  
Ground Wire in  
Conduit AWG  
(IEC) Sizes  
STACKING  
Size  
90  
80  
40  
30  
90  
80  
80  
50  
45  
45  
45  
40  
Nameplate (IEC) Sizes  
2
2
The CV-250 may be stacked three-high provided the  
bottom machine is on a stable, hard, level surface. Be  
sure that the two pins in the roof fit into the slots in the  
base of the CV-250 above it.  
56  
51  
26  
20  
59  
54  
52  
31  
30  
29  
27  
24  
6 (16mm )  
208/60  
230/60  
8 (10mm )  
2
2
6 (16mm )  
8 (10mm )  
2
2
10 (6mm )  
460/60  
10 (6mm )  
2
2
10 (6mm )  
575/60  
10 (6mm )  
2
2
4 (25 mm )  
200/50/60  
220/50/60  
230/50/60  
380/50/60  
400/50/60  
415/50/60  
440/50/60  
500/50/60  
8 (10mm )  
TILTING  
2
2
6 (16mm )  
8 (10mm )  
2
2
Do not place the machine on a surface that is inclined  
enough to create a risk of the machine falling over.  
6 (16mm )  
8 (10mm )  
2
2
8 (10mm )  
10 (6mm )  
2
2
10 (6mm )  
10 (6mm )  
2
2
10 (6mm )  
10 (6mm )  
2
2
10 (6mm )  
10 (6mm )  
2
2
10 (6mm )  
10 (6mm )  
1
Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit  
breakers which have a delay in tripping action that decreases as the magni-  
tude of the current increases.  
CV-250  
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A-3  
A-3  
INSTALLATION  
Connection of Remote Control (K857)  
FIELD INSTALLED OPTIONS  
NOTE: The K864 Remote Control Adapter is required  
to install the K857.  
For installation of compatible field installed options  
(see the ACCESSORIES section of this manual and  
refer to the instructions included with those options.  
Plug the K864 Remote Control Adapter into the power  
source's 14-pin receptacle. Plug the K857 Remote  
Control into the 6-pin receptacle of the K864 adapter.  
If possible, tape the Remote cable to the heavy output  
leads, so they can protect the smaller Remote cable  
from damage and abuse.  
REQUIRED EQUIPMENT-CONTROL  
CABLE CONNECTIONS  
Follow the instructions below which are appropriate  
for the wire feeder that will be used.  
OUTPUT CONNECTIONS  
LN-7 to CV-250  
Output cables must have Magnum Twist-Mate™ plugs  
for connection to the CV-250. Order K852-70 for con-  
2
a) Turn the CV-250 Power switch to the "OFF" posi-  
tion.  
necting 1/0-2/0 (50-70 mm ) cables. Refer to S18737  
for instructions on installing these plugs.  
b) Connect the LN-7 control cable to the wire feeder  
receptacle on the CV-250.  
Use the shortest possible cable lengths. See Table  
A.1 for recommended cable sizes based on length.  
c) See OUTPUT CONNECTIONS for connection of  
work and electrode cables.  
Connect the positive output lead to the terminal  
marked "+". The negative output lead can be hooked  
to either the low inductance terminal (marked "  
") or the high inductance terminal (marked  
LN-25 to CV-250  
"
").  
a) Turn the CV-250 Power switch to the "OFF" posi-  
tion.  
TABLE A.1  
Cable Sizes for Combined Lengths of Copper  
Electrode and Work Cable  
b) Plug a K484 jumper plug into the CV-250 wire  
feeder receptacle.  
Lengths up to  
Machine Size  
150 ft  
150 to 200 ft  
250 A 100%  
(300 A 60%)  
c) See OUTPUT CONNECTIONS for connection of  
work and electrode cables.  
2
2
)
1/0 (50mm )  
2/0 (95mm  
WARNING  
The output terminals are energized at all times when  
the K484 is plugged in.  
------------------------------------------------------------------------  
LN-742 to CV-250  
a) Turn the CV-250 Power switch to the "OFF" posi-  
tion.  
b) Connect the LN-742 control cable to the wire  
feeder receptacle on the CV-250.  
c) See OUTPUT CONNECTIONS for connection of  
work and electrode cables.  
CV-250  
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A-4  
A-4  
INSTALLATION  
PARALLELING  
The CV-250 is not designed to be paralleled with any  
other power source.  
CONNECTION OF AUXILIARY EQUIPMENT  
TO THE WIRE FEEDER RECEPTACLE  
Occasionally, it may be necessary to make connection  
to the circuits present in the 14-pin wire feeder recep-  
tacle. These circuits, such as the auxiliary voltage,  
contactor, and remote control circuits, may be  
accessed with a K867 Universal Adapter. This  
adapter plugs into the receptacle and provides the  
user with short wire leads for connections. Refer to  
the instructions provided with the K867, as well as the  
wiring diagram for the CV-250 power source, for  
details on making those connections. For your conve-  
nience, wire feeder connection details are shown in  
the DIAGRAM section.  
NOTE: If you intend to use a standard Lincoln wire  
feeder, order the appropriate input cable for  
the specific feeder. It will make all of the con-  
trol and power connections between the CV-  
250 and the wire feeder WITHOUT the need  
for a K867 Universal Adapter.  
CV-250  
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B-1  
B-1  
OPERATION  
OPERATING INSTRUCTIONS  
Read and understand this entire section before oper-  
ating the machine.  
GENERAL WARNINGS  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK  
can kill.  
• Do not touch electrically live parts  
or electrode with skin or wet  
clothing.  
• Insulate yourself from work and  
ground.  
• Always wear dry insulating  
gloves.  
FUMES AND GASES  
can be dangerous.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing  
zone.  
WELDING SPARKS  
can cause fire or  
explosion  
• Keep flammable material away.  
• Do not weld on containers that  
have held combustibles.  
ARC RAYS  
can burn.  
• Wear eye, ear and body  
protection.  
Observe additional Safety Guidelines detailed  
throughout of this manual.  
CV-250  
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B-2  
B-2  
OPERATION  
• Circuit breaker protected.  
CAUTION  
• 115 VAC, 5 amp auxiliary power available for the  
wire feeder; circuit breaker protected.  
When using a CV-250 power source with wire feed-  
ers, there will be a small spark if the electrode con-  
tacts the work or ground within several seconds after  
releasing the trigger.  
• 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.  
When used with some wire feeders with the electrical  
trigger interlock in the ON position, the arc might  
restart if the electrode touches the work or ground  
during these several seconds.  
------------------------------------------------------------------------  
DESIGN FEATURES  
GENERAL DESCRIPTION  
• "Clean" appearance and simple controls -- easy to  
operate.  
The CV-250 is a constant voltage DC power source  
designed for the GMAW process with limited FCAW  
capability as well. It features an industrial rating of  
250 amps, 30 volts, at 100% duty cycle. It complies  
with the requirements for a NEMA Class I (100) power  
source.  
• Electronic and thermostatic protection from over-  
loads.  
• Submersion dipping of assembled transformer,  
choke, and rectifier in special sealing/insulating  
material gives extra protection against moisture and  
corrosive atmospheres.  
It is available from the factory in one model only, with  
no options other than input voltage or frequency.  
• Microprocessor based Control PC Board has built-in  
diagnostic routines.  
RECOMMENDED PROCESSES AND  
EQUIPMENT  
• Compact size, requires only 19" x 26" footprint.  
• Modular construction for easy servicing.  
The CV-250 is capable of solid wire welding within the  
rated output capacity of the machine. It is also capa-  
ble of welding with the following flux-cored wires: NR-  
152, NR-211, NS-3M, NR-203 Ni 1%, and  
Outershield® 70 and 71.  
• Recessed panels protect output studs and controls.  
Large safety margins and protective circuits protect  
rectifiers from transient voltages and high currents.  
The CV-250 is recommended for use with the LN-7,  
LN-742 and LN-25 wire feeder models.  
LIMITATIONS  
The CV-250 is intended only for use with the following  
FCAW electrodes: NR-152, NR-211, NR-203 Ni 1%,  
NS-3M, Outershield 70 and 71. The machine has  
been designed primarily for the GMAW process.  
OPERATIONAL FEATURES AND  
CONTROLS  
• Two inductance positions: operator can choose the  
optimum output characteristics.  
POWER SOURCE OPERATION  
• Solid State Output Contactor: no noise, no moving  
parts to wear.  
Be sure the CV-250 is properly installed, and that all  
accessories are properly hooked up before attempting  
operation.  
• Digital Voltmeter/Ammeter is standard.  
• Power on/off switch.  
DUTY CYCLE  
250 Amps, 30 Volts at 100%  
• 42 VAC, 10 amp auxiliary power available for the  
wire feeder.  
300 Amps, 32 Volts at 60%  
Duty Cycle is based on operation for a 10 minute period.  
CV-250  
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B-3  
B-3  
OPERATION  
CONTROLS AND SETTINGS  
All operator controls and adjustments are located on the case front of the CV-250. Refer to Figures B.1, and B.2  
and corresponding explanations.  
FIGURE B.1 - CONTROL PANEL  
LOCAL  
+
-
REMOTE  
H
J
A. POWER SWITCH  
F. 42 VOLT CIRCUIT BREAKER  
G. 115 VOLT CIRCUIT BREAKER  
H. LOCAL / REMOTE SWITCH  
B. VOLTAGE ADJUSTMENT  
C. THERMAL PROTECTION INDICATION LIGHT  
D. VOLTS / AMPS SWITCH  
E. DIGITAL VOLTMETER / AMMETER  
J. WIRE FEEDER VOLTMETER SWITCH  
A. POWER SWITCH  
NOTE: Due to voltage drops in the welding cables  
and at cable connection points, the actual arc  
voltage may be lower than that displayed on  
the voltmeter. Use welding cables of the  
proper capacity and make sure all connec-  
tions are tight to minimize this effect.  
- A two-position toggle switch.Controls the  
input power to the CV-250.  
B. VOLTAGE ADJUST  
- Controls the CV-250 output voltage.  
F. 42 VOLT CIRCUIT BREAKER  
C. THERMAL PROTECTION INDICATION LIGHT  
-Protects the 42 volt 41-42 circuit in the wire  
feeder receptacle from overloads and shorts.  
If this circuit breaker opens, the CV-250 will  
work normally. However, any equipment  
powered by the 42 volt circuit will not work.  
- Indicates that the protection thermostat has  
activated. The digital meter will display "E10"  
when this occurs. When the light turns off,  
the machine will be capable of supplying  
welding output power again.  
G. 115 VOLT CIRCUIT BREAKER  
NOTE: Leaving the power switch in the "ON" posi-  
tion will result in the most rapid cooling.  
-Protects the 115 volt 31-32 circuit in the wire  
feeder receptacle from overloads and shorts.  
If this circuit breaker opens, the CV-250 will  
work normally. However, any equipment  
powered by the 115 volt circuit will not work.  
D. VOLTS/AMPS SWITCH  
- Selects either output current or arc voltage  
to be displayed on the digital meter.  
H. LOCAL/REMOTE SWITCH  
E. DIGITAL VOLTMETER/AMMETER  
-Determines whether the welding voltage is  
controlled at the CV-250, or controlled  
remotely by a remote output control (such as  
a K857).  
- Displays the CV-250 output current, or the  
arc voltage.  
CV-250  
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B-4  
B-4  
OPERATION  
-When welding electrode negative (most  
Innershield electrodes) set the switch to "-".  
J. WIRE FEEDER VOLTMETER SWITCH  
-This switch selects the polarity of the wire  
feeder voltmeter, if so equipped. When weld-  
ing electrode positive (MIG, Outershield and  
some Innershield processes) set the switch  
to "+".  
-This switch has no effect on the welding  
polarity. In fact, if the wire feeder being used  
does not have a voltmeter, the setting of this  
switch has no effect.  
GRAPHIC SYMBOLS THAT APPEAR ON  
THIS MACHINE OR IN THIS MANUAL  
THERMAL PROTEC-  
TION INDICATOR  
LIGHT  
OFF  
CIRCUIT  
BREAKER  
ON  
CLOCKWISE ROTA-  
TION INCREASES  
VOLTAGE  
AC  
POWER  
REMOTE OUTPUT  
VOLTAGE CONTROL  
LOCAL OUTPUT  
VOLTAGE CONTROL  
INDICATES WARNING INFORMATION  
LOCATED ON RIGHT CASE SIDE  
WARNING  
CV-250  
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B-5  
B-5  
OPERATION  
OUTPUT PANEL CONNECTIONS  
FIGURE B.2 - OUTPUT PANEL  
D
C
B
A
A. POSITIVE OUTPUT CONNECTION  
B. LOW INDUCTANCE NEG. CONNECTION  
C. HIGH INDUCTANCE NEG. CONNECTION  
D. WIRE FEEDER RECEPTACLE  
A., B., C. OUTPUT CONNECTORS  
C. HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION.  
-Each connector is a Magnum Twist-Mate™,  
receptacle. Insert a mating Twist-Mate™  
plug, and twist clockwise to secure.  
-The high inductance connection is more suit-  
able for short arc welding heavier weldments  
or when using 75% Argon/25% CO shield-  
2
ing gas. This connection produces a softer  
arc and a flatter bead with more wash-in than  
the low inductance connection. A spray type  
transfer is possible with either connection.  
For GMAW processes, and most FCAW  
processes, the positive output connection  
goes to the wire feeder. One of the negative  
output connections goes directly to the work.  
A. POSITIVE OUTPUT CONNECTION.  
D. WIRE FEEDER RECEPTACLE  
-14-pin MS style receptacle for wire feeder.  
Provides connections for auxiliary power,  
contactor closure, remote output control, wire  
feeder voltmeter sense lead, and ground.  
B. LOW INDUCTANCE NEGATIVE CONNECTION.  
-The low inductance connection is typically  
used for short arc welding of mild steel, par-  
ticularly on thin materials or when using CO  
shielding gas.  
2
CV-250  
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B-6  
B-6  
OPERATION  
STARTING THE MACHINE  
AUXILIARY POWER  
The power switch at the extreme right side of the con-  
trol panel energizes the CV-250.  
42 volt AC auxiliary power, as required for some wire  
feeders, is available through the wire feeder recepta-  
cle. A 10 amp circuit breaker protects the 42 volt cir-  
cuit from overloads.  
ADJUSTING THE OUTPUT VOLTAGE  
USING THE DIGITAL METER  
CV-250 machines can also supply 115 volt AC auxil-  
iary power through the wire feeder receptacle. A 5  
amp circuit breaker protects the 115 volt circuit from  
overloads.  
The digital meters in the CV-250 incorporate a voltage pre-  
set function. This allows the operator to set the desired  
welding voltage before striking an arc. The digital meters  
can also display welding current.  
NOTE: Do not use circuits 2 or 4 for control of auxil-  
iary loads. (The 2-4 circuit is isolated from the  
31-32 and 41-42 circuits.)  
To make use of the voltage preset function, the Volts/Amps  
switch must be in the "Volts" position. Turn the Voltage  
Adjust knob until the digital meter displays the desired weld-  
ing voltage. (See below if an external power source remote  
control is installed.)  
CAUTION  
Note that some types of equipment, especially pumps  
and large motors, have starting currents which are  
significantly higher than their running current. These  
higher starting currents may cause the circuit breaker  
to open. If this situation occurs, the user should refrain  
from using the CV-250 auxiliary power for that equip-  
ment.  
When an arc is struck, the digital meter displays the actual  
welding voltage, as measured at the CV-250 output termi-  
nals.  
NOTE: The arc voltage at the electrode may be as much as  
two volts different from the CV-250 output terminal  
voltage. This is due to voltage drops present in the  
welding cables, cable connections, and welding  
gun. To minimize these drops, use cables of ade-  
quate capacity, and make sure all connections are  
clean and tight. Because of these voltage drops,  
you may have to preset the CV-250 for a slightly  
higher welding voltage than your procedure calls for.  
___________________________________________  
OVERLOAD PROTECTION  
This welder has thermostatic protection from exces-  
sive duty cycles, overloads, loss of cooling, and high  
ambient temperatures. When the welder is subjected  
to an overload or loss of cooling, a thermostat will  
open. This condition will be indicated by the illumina-  
tion of the yellow Thermostatic Protection Light on the  
case front (see Figure B.1).The fan will continue to run  
to cool the power source. No welding is possible until  
the machine is allowed to cool and the Thermostatic  
Protection Light goes out.  
To read welding current, set the Volts/Amps switch to the  
"Amps" position. The welding current will be displayed  
whenever an arc is struck.  
LOCAL/REMOTE SWITCH OPERATION  
If voltage control is desired at the CV-250, the Local/Remote  
switch must be in the "Local" position. The Voltage Adjust  
on the front panel can be used to adjust the CV-250 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 Figure  
B.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 the  
CV-250 output.  
CV-250  
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C-1  
C-1  
ACCESSORIES  
FACTORY INSTALLED  
COMPATIBLE LINCOLN EQUIPMENT  
OPTIONS/ACCESSORIES  
The CV-250 is intended for use with the LN-7, LN-742,  
and LN-25 wire feed units. Use the Cables / Kits listed  
below to make connection easily:  
There are no factory installed options/accessories on  
the CV-250.  
LN-7 / LN-7GMA  
LN-25  
Requires K480 Input Cable  
FIELD INSTALLED OPTIONS  
Requires K484 Jumper Plug Kit  
REMOTE VOLTAGE CONTROL (K857)  
LN-25 w/K444-1  
Remote Voltage  
Control Kit  
Requires K864 Remote Control  
Adapter and K484 Jumper Plug  
Kit  
The K857 consists of a control box with 25 feet (7.6  
m) of four conductor cable. Installation of a K857  
Remote Voltage Control in the CV-250 requires a  
K864 Remote Control Adapter. Refer to the instruc-  
tions provided with the K857 for hookup to the CV-  
250. When properly connected, and with the CV-250  
Local-Remote Switch in the "Remote" position, the  
K857 functions the same as the CV-250 Voltage  
Adjust control, enabling minimum to maximum output  
voltage adjustment of the CV-250.  
LN-742 / LN-742H  
Requires K591 Input Cable  
UNDERCARRIAGE (K835)  
Includes front casters, a handle, a bracket, and a rear  
wheeled platform that is capable of carrying one gas  
cylinder. The CV-250 lifting eye is not functional with  
the K835 undercarriage installed.  
TWO-CYLINDER UNDERCARRIAGE (K874)  
Platform type undercarriage that can accommodate  
either one or two gas bottles, or one gas bottle and a  
Magnum water cooler. The CV-250 lifting eye is not  
functional when the K874 undercarriage is installed.  
WIRE FEEDER SWIVEL MOUNT (K178-1)  
Allows an LN-7 or LN-742 to be securely mounted on  
the roof of a CV-250.  
UNIVERSAL ADAPTER (K867)  
Provides a means of connecting auxiliary equipment  
to the wire feeder receptacle on the CV-250 power  
source. Consists of a 14-pin MS-type (Amphenol)  
plug with 8 inch (0.2 meter) long flex leads, one for  
each circuit present in the wire feeder receptacle. Not  
required when using a standard wire feeder input  
cable, such as a K480, with a Lincoln wire feeder.  
CV-250  
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D-1  
D-1  
MACHINE AND CIRCUIT PROTECTION  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ELECTRIC SHOCK can kill.  
The CV-250 Control PC Board has built-in diagnostic  
routines to alert the operator when trouble exists.  
When a trouble condition occurs, the CV-250 meter  
will display an error code, in the form "EXX", where  
"XX" refers to a specific error. See TROU-  
BLESHOOTING section for an explanation of the error  
codes.  
• Only qualified personnel should  
perform this maintenance.  
• Turn the input power OFF at the  
disconnect switch or fuse box  
before working on this  
equipment.  
The power source is thermostatically protected  
against overload or insufficient cooling. If the machine  
is overloaded, the thermostat will open, thermal pro-  
tection indicator light will turn on, and the output will  
be zero. The fan will continue to run and auxiliary  
power will still be available. The thermostat will  
remain open until the machine cools, at which time it  
will close and the output will again be available.  
• Do not touch electrically hot  
parts.  
GENERAL MAINTENANCE  
The CV-250 is electronically protected against over-  
loads and accidental short circuits. The overload pro-  
tection circuit automatically reduces the output current  
to a safe value when an overload is detected. If the  
circuitry senses a short circuit, it will shut off the CV-  
250 output. The short circuit protection circuit can be  
reset by turning the CV-250 Power switch OFF for at  
least 10 seconds. Remove the short before turning  
the Power switch ON again.  
1. The fan motor has sealed bearings which require  
no service.  
2. In extremely dusty locations, dirt may clog the air  
channels causing the welder to run hot with prema-  
ture tripping of thermal protection. Blow out the  
welder with low pressure air at regular intervals to  
eliminate excessive dirt and dust build-up on inter-  
nal parts.  
CV-250  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
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 and  
machine operator and will invalidate your factory warranty. For your safety and to avoid  
Electrical Shock, please observe all safety notes and precautions detailed throughout this  
manual.  
__________________________________________________________________________  
Step 2. PERFORM EXTERNAL TESTS.  
The second column labeled “POSSIBLE  
AREAS OF MISADJUSTMENT(S)” lists the  
obvious external possibilities that may con-  
tribute to the machine symptom. Perform  
these tests/checks in the order listed. In  
general, these tests can be conducted with-  
out removing the case wrap-around cover.  
This Troubleshooting Guide is provided to  
help 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 may  
exhibit. Find the listing that best describes  
the symptom that the machine is exhibiting.  
Step 3. PERFORM COMPONENT TESTS.  
If you have exhausted all of the recom-  
mended tests in Step 2, Consult your Local  
Authorized Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform  
the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC  
FIELD SERVICE FACILITY for assistance before you proceed.  
_____________________________________________________________________  
CV-250  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
BUILT-IN DIAGNOSTIC ROUTINES AND ERROR CODES  
The CV-250 Meter PC Board displays error codes when certain trouble conditions exist. The error codes, trouble  
conditions, and possible remedies are listed below.  
ERROR  
TROUBLE  
REMEDY  
CODE  
E00  
1. Output short circuited.  
1. Turn power off. Remove short circuit.  
2. May be encountered while  
starting or welding with 1/16" alu-  
minum wire.  
2. a) Turn power off to clear error. Use recommended  
wfs, voltage settings and angle of approach of wire  
to work.  
b) If problem still persists, call Local Lincoln  
Authorized Field Service Facility.  
E10  
Thermostat circuit has opened.  
Memory error.  
Allow machine to cool. Be sure to provide adequate  
ventilation for machine.  
E20  
E30  
See PC Board Troubleshooting Procedure.  
1. Voltage Adjust potentiometer not  
connected.  
2. Remote Control not functioning  
correctly.  
1. Check wiring between Voltage Adjust and the  
Control PC Board.  
2. See Options Troubleshooting Guide.  
E40  
E50  
E60  
Input line voltage too low.  
Input line voltage too high.  
Overload condition.  
Turn power off. Insure machine input voltage is within  
specifications. Turn power back on.  
Turn power off. Insure machine input voltage is within  
specifications. Turn power back on.  
Reduce load on machine.  
If, after attempting the remedies listed above, the error condition still exists, the problem may be with the wiring in  
the following areas: the shunt (leads 218 and 219), or voltage feedback (leads 213B, 214B and 224B).  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
MACHINE TROUBLESHOOTING GUIDE  
Not all trouble conditions can be recognized by the PC board, and displayed as error codes. The following guide  
covers most other trouble conditions.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
PROBLEMS  
Machine has no output.  
1. Secondary contactor circuit (2  
and 4 wire feeder receptacle) not  
working.  
1. Check 2 and 4 circuit wiring.  
2. Repair connection.  
2. Electrode or work lead loose or  
broken.  
3. Defective PC Board.  
3. See PC Board Troubleshooting  
Procedure.  
4. Protective circuits operating due 4. Turn power off. Remove output short  
to output short circuit.  
circuit.  
5. If using an LN-25, K484 jumper  
plug kit not making connection  
between 2 & 4 in wire feeder  
receptacle.  
5. Check for continuity between pins C  
& D in the K484.  
6. If welding with 1/16" aluminum  
wire and machine is flashing E00.  
6. a) Turn power off to clear error. Use  
recommended wfs, voltage set-  
tings and angle of approach of  
wire to work.  
b) If problem still persists, call Local Lincoln  
Authorized Field Service Facility.  
Machine has minimum output and no 1. Voltage Control misconnected.  
control.  
1. Voltage Control wiring.  
Machine has low output and no con- 1. Open in feedback circuitry.  
trol.  
1. Check wiring and control and PC  
board wiring harness plugs.  
2. Faulty PC Board.  
2. See PC Board Troubleshooting  
Procedure.  
3. Voltage Adjust potentiometer  
circuit open (lead 75).  
3. Check and replace potentiometer if  
faulty. Check wiring of lead #75.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
PROBLEMS  
Thermal Protection Indicator light is 1. Thermostat circuit has opened.  
on.  
1. Allow machine to cool. Be sure to  
provide adequate ventilation for  
machine.  
2. Faulty Control PC Board.  
2. See PC Board Troubleshooting  
Procedure.  
Machine does not have maximum  
output  
1. Faulty Control PC Board.  
1. See PC Board Troubleshooting  
Procedure.  
2. Voltage Adjust potentiometer  
defective.  
2. Check and replace if faulty.  
3. Voltage Adjust potentiometer  
leads open.  
3. Check and repair broken leads.  
Machine will not shut off.  
1. Defective power switch.  
1. Replace.  
Variable or sluggish welding arc.  
1. Poor work or electrode  
connection.  
1. Check and clean all connections.  
2. Welding leads too small.  
2. Check table in this manual.  
3. Welding current or voltage  
too low.  
3. Check procedures for recommended  
settings.  
4. Defective SCR bridge.  
1. Faulty Meter PC board.  
4. Check and replace if defective.  
Digital meters do not light  
- or -  
Digital meter display is incorrect.  
1. See PC Board Troubleshooting  
Procedure.  
2. Faulty Control PC Board.  
2. See PC Board Troubleshooting  
Procedure.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
PROBLEMS  
Poor arc striking with semiautomatic 1. Poor work connection.  
wire feeders.  
1. Work connection must be adequate  
for application.  
2. Improper procedures.  
2. Adjust procedures for improved start-  
ing.  
3. Wire feed acceleration too fast or 3. Adjust wire feeder acceleration set-  
too slow.  
ting, if provided.  
4. Defective PC Board.  
4. See PC Board Troubleshooting  
Procedure.  
Poor arc characteristics  
1. Control PC Board defective.  
1. See PC Board Troubleshooting  
Procedure.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
OPTIONS TROUBLESHOOTING GUIDE  
K857 (or other) Remote Output Control  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENTS(S)  
RECOMMENDED  
COURSE OF ACTION  
PROBLEMS  
1. Local/Remote switch in wrong  
position.  
Voltage control not functioning on  
Remote Control.  
1. Place switch in "Remote".  
2. Faulty Local/Remote switch.  
2. Check and replace if found faulty.  
3. Check and replace if found faulty.  
3. Faulty Remote Control poten-  
tiometer.  
4. Leads or connections open in  
control circuit.  
4. Check all leads and connections,  
internal or remote, for continuity;  
repair if necessary.  
5. Faulty Control PC board.  
5. See PC Board Troubleshooting  
Procedure.  
Voltage Adjust not functioning on the 1. Local/Remote switch in the  
1. Place switch in "Local" position.  
2. Check and replace if found faulty.  
3. Check and replace if found faulty.  
machine.  
wrong position.  
2. Faulty Local/Remote switch.  
3. Faulty Voltage Adjust  
potentiometer.  
4. Leads or connections open in  
control circuit.  
4. Check all leads and connections,  
internal or remote, for continuity;  
repair if necessary.  
5. Faulty Control PC board.  
5. See PC Board Troubleshooting  
Procedure.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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E-7  
E-7  
TROUBLESHOOTING  
Procedure for Replacing PC Boards  
PC BOARD TROUBLESHOOTING  
PROCEDURES  
WARNING  
CONTROL PC BOARD  
ELECTRIC SHOCK can kill.  
• Have a qualified individual install and  
service this equipment.  
The Control PC Board controls all machine functions  
including the thermal protection indicator light and the  
Meter PC Board. Most problems, if not caused by  
faulty wiring machine misuse, will stem from a faulty  
Control PC Board.  
• Turn the power source input power off  
at the disconnect switch before work-  
ing on this equipment.  
• Do not touch electrically hot parts.  
---------------------------------------------------------------------  
Perform the following diagnostic procedure before  
replacing the Control PC Board.  
Before replacing a PC board which is suspected of  
being defective, visually inspect the PC board in ques-  
tion for any electrical or mechanical damage to any of  
its components and conductors on the back of the  
board.  
1. Turn off the input power at the fuse box.  
2. Check for loose connections in the PC Board  
plugs, particularly J3.  
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 old  
PC board to see if the problem still exists. If it  
does no longer exist with old PC board:  
3. Disconnect the J3 plug from the Control PC Board.  
Measure the resistance between the following wire  
terminals in the plug:  
A) Between wire #200 and wire #201.  
B) Between wire #202 and wire #203.  
1. Check the PC board harness connector pins for  
corrosion, contamination, or looseness.  
Both of these resistances should be less than 1 ohm.  
2. Check leads in the plug harness for loose or  
intermittent connection.  
If these resistances are not less than 1 ohm, check the  
wiring back to the main transformer.  
b. If PC board is visibly damaged electrically, before  
possibly subjecting the new PC board to the same  
cause of failure, check for possible shorts, opens,  
or grounds caused by:  
If these voltages are less than 1 ohm, refer to  
"Procedure for Replacing PC Boards."  
METER PC BOARD  
1. Frayed or pinched lead insulation.  
2. Poor lead termination, such as a poor contact  
or a short to adjacent connection or surface.  
When the Meter PC Board malfunctions, first determine  
if the rest of the machine functions correctly. If so, then  
the problem is in either the harness between the meter  
and control boards, or in the meter board itself. Refer  
to "Procedure for Replacing PC Boards". As a last  
resort, the Control PC Board may have to be replaced.  
3. Shorted or open motor leads, or other external  
leads.  
4. Foreign matter or interference behind the PC  
boards.  
c. If PC board is visibly damaged mechanically,  
inspect for cause, then remedy before installing a  
replacement PC board.  
If there is damage to the PC board or if replacing  
PC board corrects problem, return it to the local  
Lincoln Electric Field Service Shop.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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E-8  
E-8  
TROUBLESHOOTING  
OUTPUT VOLTAGE  
The open circuit voltage of the machine should be 10  
to 43 volts. If any other condition exists, refer to the  
Troubleshooting Guide.  
FAULT PROTECTION OPERATION  
The overload protection circuit on the PC Board will  
cause the CV-250 meter to display "E60". This pro-  
tection circuit will reset itself automatically. The short  
circuit protection circuit will cause the meter to display  
"E00". The CV-250 power switch must be turned  
"OFF" and then "ON" to return the machine to normal  
output.  
CHECKING SNUBBER CIRCUIT  
In case of an SCR malfunction or failure, the snubber  
assembly should be checked. Disconnect the input  
power to the CV-250 at the fuse box and remove the  
right side of the machine.  
1.Visually inspect the snubber PC Board assembly  
(located below the Control PC board on the case front  
for overheated components or damaged compo-  
nents).  
OPTIONAL K857 REMOTE CONTROL  
CHECK  
Disconnect the remote output control and connect an ohm-  
meter between pins C and B and rotate the rheostat in the  
remote control. The resistance reading should go from zero  
to 10K ohms. Repeat with ohmmeter across A and B with  
the same results. Connect ohmmeter across A and C. The  
reading should be 10K ohms. A lower reading will indicate a  
shorted or partially shorted rheostat. A very high reading  
will indicate an open rheostat. In either of the last two  
cases, replace the rheostat.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
CV-250  
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F-1  
F-1  
DIAGRAMS  
R 2  
+
2 2 4 A  
8
8
8
CV-250  
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F-2  
F-2  
DIAGRAMS  
CV POWER SOURCE TO AN LN-7 AND K857  
CV-250  
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F-3  
F-3  
DIAGRAMS  
CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER  
CV-250  
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F-4  
F-4  
DIAGRAMS  
CV POWER SOURCE TO A K867 / K775 / LN-7  
CV-250  
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F-5  
F-5  
DIAGRAMS  
CV POWER SOURCE TO AN LN-25  
CV-250  
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F-6  
F-6  
DIAGRAMS  
CV POWER SOURCE TO AN LN-25 / K444-1  
CV-250  
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F-7  
F-7  
DIAGRAMS  
LINCOLN POWER SOURCE TO AN LN-742  
CV-250  
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F-8  
F-8  
DIAGRAMS  
K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS  
CV-250  
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F-9  
F-9  
DIAGRAMS  
TWIST-MATE CABLE PLUG INSTALLATION INSTRUCTIONS  
TWIST-MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS  
TURN THE POWER SWITCH OF THE WELDING POWER  
SOURCE "OFF" BEFORE INSTALLING PLUGS ON CABLES  
OR WHEN CONNECTING OR DISCONNECTING PLUGS TO  
WELDING POWER SOURCE.  
CHECK THAT THE CONNECTOR BOOT IS MARKED FOR THE  
APPROPRIATE CABLE SIZE PER TABLE BELOW; AND  
SKIN CABLE JACKET TO LENGTH SPECIFIED:  
1.  
AMERICAN (EUROPEAN) RANGE  
CABLE SKIN LENGTH  
BOOT MARKING  
CABLE SIZE  
2
1 INCH (25.4mm)  
1 INCH (25.4mm)  
mm )  
35-50  
50-70  
70-95  
#2-#1 (  
35-50  
2
mm )  
1/0-2/0  
2/0-3/0  
(
50-70  
(70-95  
2
1.5 INCH (38.1mm)  
mm )  
If necessary, trim cable end of boot at groove(s) to match cable  
diameter. Boot must fit tightly enough to seal around outside  
diameter of cable. NOTE: Some boots are designed to accommodate  
2.  
different cable diameters without trimming. These boots do not  
have grooves at the cable end. Soap or other non petroleum  
based lubricant will help to slide the boot over the cable.  
BOOT  
Slide rubber boot onto cable end.  
3.  
WELDING CABLE  
SEE  
ABOVE  
TRIM  
Slide the copper tube into the brass plug.  
Insert cable into copper tube.  
4.  
5.  
SET SCREW  
(70-95 size may  
have 2 set  
screws)  
BRASS PLUG  
COPPER TUBE  
Tighten set screw(s) to collapse copper tube. Screw(s)  
must apply firm pressure against welding cable. The top of the  
set screw(s) will be nearly flush or below the surface of the  
brass plug after tightening.  
6.  
7.  
Slide rubber boot over brass plug. The rubber boot must be  
positioned to completely cover all electrical surfaces after  
the plug is locked into the receptacle.  
CV-250  
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F-10  
F-10  
DIAGRAMS  
CONNECTION OF NON-LINCOLN WIRE FEEDERS  
CV-250  
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F-11  
F-11  
DIAGRAMS  
DIMENSION PRINT  
CV-250  
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Now Available...12th Edition  
New Lessons in Arc Welding  
The Procedure Handbook of Arc Welding  
Lessons, simply written, cover manipulatory techniques;  
machine and electrode characteristics; related subjects,  
such as distortion; and supplemental information on arc  
welding applications, speeds and costs. Practice materials,  
exercises, questions and answers are suggested for each  
lesson.  
With over 500,000 copies of previous editions published  
since 1933, the Procedure Handbook is considered by many to  
be the “Bible” of the arc welding industry.  
This printing will go fast so don’t delay. Place your  
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The hardbound book contains over 750 pages of welding  
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$5.00 postage paid U.S.A. Mainland  
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The book contains the latest information and application  
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and ask for bulletin ED-80 or call 216-383-2259 and ask for the  
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187 pages with more than 100 illustrations. Size 8-1/2” x 11”  
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Lincoln Welding School  
BASIC COURSE  
$700.00  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à lécart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYERS SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES 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 A  
ETRE 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.  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant lentre- Nopérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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