Lincoln Electric IDEALARC CV-250 manual

IDEALARC C V -250 OPERA TOR’S MANUAL IM505 December, 1999 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[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can b urn. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCA UTIONS 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Select Suitable Location .......................................................[...]

A-1 CV-250 A-1 INST ALLA TION TECHNICAL SPECIFICA TIONS – IDEALARC CV -250 Code Number 10013 10014 Volts at Rated Amperes 30 32 30 Auxiliary Power 42 Volts AC, 10 Amps 115 Volts AC, 5 Amps ( Both Circuit Breaker Protected) Idle Current - Amps 11/10/5 Input Current at Rated Output 100% Duty Cycle 56/51/26 60% Duty Cycle 62/56/28 100% Duty Cycle 51[...]

A-2 INST ALLA TION CV-250 A-2 Read entire installation section before starting installation. SAFETY PRECA UTIONS SELECT SUIT ABLE LOCA TION 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-3 INST ALLA TION CV-250 A-3 FIELD INST ALLED OPTIONS For installation of compatible field installed options (see the ACCESSORIES section of this manual and refer to the instructions included with those options. REQUIRED EQ UIPMENT -CONTROL CABLE CONNECTIONS Follow the instructions below which are appropriate for the wire feeder that will be used.[...]

A-4 INST ALLA TION CV-250 A-4 P ARALLELING The CV-250 is not designed to be paralleled with any other power source. CONNECTION OF A UXILIAR Y EQUIPMENT T O THE WIRE FEEDER RECEPT A CLE 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, c[...]

B-1 OPERA TION B-1 CV-250 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. [...]

B-2 OPERA TION B-2 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. 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 [...]

B-3 OPERA TION B-3 A. POWER SWITCH - A two-position toggle switch.Controls the input power to the CV-250. B. VOLTAGE ADJUST - Controls the CV-250 output voltage. C. THERMAL PROTECTION INDICATION LIGHT - Indicates that the protection thermostat has activated. The digital meter will display "E10" when this occurs. When the light turns off, [...]

B-4 OPERA TION B-4 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 "+". - When welding electrode negative (most Innershield electrodes) set the switch to "-". - Th[...]

B-5 OPERA TION B-5 CV-250 A., B., C. OUTPUT CONNECTORS -Each connector is a Magnum Twist-Mate™, receptacle. Insert a mating Twist-Mate™ plug, and twist clockwise to secure. For GMAW processes, and most FCAW processes, the positive output connection goes to the wire feeder. One of the negative output connections goes directly to the work. A. POS[...]

B-6 OPERA TION B-6 ST AR TING THE MA CHINE The power switch at the extreme right side of the con- trol panel energizes the CV-250. ADJUSTING THE OUTPUT V OL T A GE USING THE DIGIT AL METER 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[...]

C-1 A CCESSORIES C-1 F A CT OR Y INST ALLED OPTIONS/A CCESSORIES There are no factory installed options/accessories on the CV-250. FIELD INST ALLED OPTIONS REMO TE V OL T A GE CONTR OL (K857) 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 R[...]

D-1 MAINTENANCE D-1 SAFETY PRECA UTIONS GENERAL MAINTENANCE 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 excessiv[...]

E-1 TR OUBLESHOO TING E-1 CV-250 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 m[...]

E-2 TR OUBLESHOO TING E-2 CV-250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION ERROR CODE TR[...]

E-3 TR OUBLESHOO TING E-3 CV-250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PROBLEMS PROB[...]

E-4 TR OUBLESHOO TING E-4 CV-250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PROBLEMS PROB[...]

E-5 TR OUBLESHOO TING E-5 CV-250 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CA UTION PROBLEMS PROB[...]

E-6 TR OUBLESHOO TING E-6 CV-250 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. CA UTION Observe all Safety Guidelines detailed throughout this manual PROBLEMS PROB[...]

E-7 TR OUBLESHOO TING E-7 CV-250 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. CA UTION Procedure f or Replacing PC Boar ds Before replacing a PC board which is su[...]

E-8 TR OUBLESHOO TING E-8 CV-250 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. CA UTION OUTPUT V OL T A GE The open circuit voltage of the machine should be 10 to [...]

F-1 DIA GRAMS F-1 CV-250 CONNECTOR CAVITY NUMBERING SEQUENCE (COMPONENT SIDE OF P. C. BOARD) ELECTRICAL SYMBOLS PER E1537 + - L1 SECONDARY THERMOSTAT 222 223 224 D4 C1 C2 C3 C4 + + + + R1 SCR2 D2 D5 222 204A 204D CONTROL P. C. BOARD 221 6 PIN 4 PIN 8 PIN SNUBBER/BYPASS P.C. BOARD 224 224A 224A 10A CIRCUIT BREAKER CB1 L1 CHOKE 2 42V 12V 12V - 204C 2[...]

F-2 DIA GRAMS F-2 CV-250 CV PO WER SOURCE T O AN LN-7 AND K857 Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE[...]

F-3 DIA GRAMS F-3 CV-250 CV PO WER SOURCE T O A K867 UNIVERSAL AD APTER N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. 76 82 81 SPARE 2 4 41 42 31 32 GND 21 77 75 REMOTE OUTPUT CONTROL N.D. 2 4 10K MIN. Only qualified persons should install, use or service this machine. [...]

F-4 DIA GRAMS F-4 CV-250 CV PO WER SOURCE T O A K867 / K775 / LN-7 N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. SPARE 82 81 42 41 31 32 2 4 21 GND 75 76 77 31 32 2 4 21 GND N.C. K291 OR K404 INPUT CABLE K775 OPTIONAL REMOTE CONTROL K867 UNIVERSAL ADAPTER PLUG 75 76 77 GREEN[...]

F-5 DIA GRAMS F-5 CV-250 CV PO WER SOURCE T O AN LN-25 Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPL[...]

F-6 DIA GRAMS F-6 CV-250 CV PO WER SOURCE T O AN LN-25 / K444-1 Only qualified persons should install, use or service this machine. using the disconnect switch at the fuse box WARNING Turn off input power to the Welding Power Source Before connecting the wire feeder. ELECTRIC SHOCK CAN KILL N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCL[...]

F-7 DIA GRAMS F-7 CV-250 LINCOLN PO WER SOURCE T O AN LN-742 Only qualified persons should install, use or service this machine. WARNING ELECTRIC SHOCK CAN KILL ELECTRODE CABLE - + 14 PIN AMPHENOL POWER SOURCE LINCOLN TO WORK LN-742 WIRE FEEDER Power Source before connecting the wire feeder. Turn off (0) the power switch on the Welding AND 14-PIN C[...]

F-8 DIA GRAMS F-8 CV-250 K867 UNIVERSAL AD APTER INST ALLA TION AND CONNECTION INSTRUCTIONS INSTALLATION INSTRUCTIONS THIS CONNECTOR IS MEANT TO BE USED WITH LINCOLN POWER SOURCES WHICH HAVE A 14-PIN TO ANY OF THE 14 CIRCUITS PRESENT IN THE WIRE FEEDER RECEPTACLE. WIRE FEEDER RECEPTACLE. IT IS DESIGNED TO ALLOW THE USER TO MAKE CONNECTIONS CONSULT [...]

F-9 DIA GRAMS F-9 CV-250 TWIST -MA TE CABLE PLUG INST ALLA TION 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. 1. WELDING CABLE BOOT TRIM Slide the copper tube into the brass plug. Insert cable into copper tube. COPPE[...]

F-10 DIA GRAMS F-10 CV-250 CONNECTION OF NON-LINCOLN WIRE FEEDERS[...]

F-11 DIA GRAMS F-11 CV-250 DIMENSION PRINT 5-18-90J N.A. N.A. N.A. N.A. FOUR SLOTS IN BASE FOR MOUNTING WELDER DOWN USING 5/16 SCREWS 1.68 N.B. N.B. HANDLE CONFIGURATION ON EARLIER MODELS. 20.05 (509) 19.65 (499) 19.20 (487) 41.58 (1056) 26.00 (660) 3.61 (91) 12.60 (320) (42.7) 11.99 (304) 3.90 (99) .28 (7.0) 1.00 (25.4) 23.62 (600) 6.20 (157) 30.9[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA EL[...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fr[...]

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