RETURN TO MAIN MENU
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
Download from Www.Somanuals.com. All Manuals Search And Download.
ii
ii
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
Download from Www.Somanuals.com. All Manuals Search And Download.
iii
iii
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
Download from Www.Somanuals.com. All Manuals Search And Download.
iv
iv
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
Download from Www.Somanuals.com. All Manuals Search And Download.
v
v
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.
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
F-1
F-1
DIAGRAMS
R 2
+
2 2 4 A
8
8
8
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-2
F-2
DIAGRAMS
CV POWER SOURCE TO AN LN-7 AND K857
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-3
F-3
DIAGRAMS
CV POWER SOURCE TO A K867 UNIVERSAL ADAPTER
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-4
F-4
DIAGRAMS
CV POWER SOURCE TO A K867 / K775 / LN-7
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-5
F-5
DIAGRAMS
CV POWER SOURCE TO AN LN-25
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-6
F-6
DIAGRAMS
CV POWER SOURCE TO AN LN-25 / K444-1
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-7
F-7
DIAGRAMS
LINCOLN POWER SOURCE TO AN LN-742
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-8
F-8
DIAGRAMS
K867 UNIVERSAL ADAPTER INSTALLATION AND CONNECTION INSTRUCTIONS
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
F-10
F-10
DIAGRAMS
CONNECTION OF NON-LINCOLN WIRE FEEDERS
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
F-11
F-11
DIAGRAMS
DIMENSION PRINT
CV-250
Download from Www.Somanuals.com. All Manuals Search And Download.
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
order now using the coupon below.
528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
The hardbound book contains over 750 pages of welding
information, techniques and procedures. Much of this material
has never been included in any other book.
$5.00 postage paid U.S.A. Mainland
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate headquarters in Cleveland, Ohio. Over 100,000 stu-
dents have graduated. Tuition is low and the training is
“hands on”
How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and
draftsmen use the “short-cut” language of symbols to pass
on assembly and welding information to shop personnel.
For details write:
Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear
in their assembled form.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the
Welding School Registrar.
187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
Lincoln Welding School
BASIC COURSE
$700.00
$4.50 postage paid U.S.A. Mainland
5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4thClass Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00
$10.00
$15.00
For order value up to $49.99
For order value between $50.00 & $99.99
For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)
Name:
_______________________________________________
CHECK ONE:
Please Invoice (only if order is over $50.00)
Address: _______________________________________________
_______________________________________________
Check or Money Order Enclosed, U.S. Funds only
Credit Card -
Telephone:_______________________________________________
Signature as it appears on Charge Card:
______________________
Account No.
|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|
Exp Date
|M_o|n_th| |_|_|
Year
USE THIS FORM TO ORDER:
BOOKS OR FREE INFORMATIVE CATALOGS
Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School
Titles:
Price
$5.00
$15.00
$4.50
$5.00
Code
L
PH
H
IM
NA
AC
Quantity
Cost
(ED-80)
New Lessons in Arc Welding
Procedure Handbook “Twelfth Edition”
How to Read Shop Drawings
Incentive Management
Seminar Information
(ED-45)
Educational Video Information
(ED-93)
A New Approach to Industrial Economics $5.00
The American Century of John C. Lincoln $5.00
James F. Lincoln Arc Welding
Foundation Book Information
Welding Preheat Calculator
Pipe Welding Charts
$3.00
$4.50
WC-8
ED-89
(JFLF-515)
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
Download from Www.Somanuals.com. All Manuals Search And Download.
● 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 l’écart 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 MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S 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.
Download from Www.Somanuals.com. All Manuals Search And Download.
● 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 l’entre- ● N’opérez 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.
Download from Www.Somanuals.com. All Manuals Search And Download.
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.
|