Lincoln Electric IDEALARC CV-250, Operator'S Manual

Page 1: ...RATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers 100...

Page 2: ...WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for co...

Page 4: ...vent 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...

Page 5: ...opri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse p...

Page 6: ...e information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes...

Page 7: ...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...

Page 8: ...Amps 250 300 250 Normal Open Circuit Voltage 10 43 MAX OCV 50 Input kVA 60 Load 22 3 100 Load 20 3 Power Factor at 100 Load 53 Standard Voltage 208 230 460 3 60 230 460 575 3 60 Duty Cycle 100 Duty C...

Page 9: ...s 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...

Page 10: ...re feeder receptacle on the CV 250 c See OUTPUT CONNECTIONS for connection of work and electrode cables Connection of Remote Control K857 NOTE The K864 Remote Control Adapter is required to install th...

Page 11: ...iversal 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 th...

Page 12: ...umes 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 RA...

Page 13: ...Digital Voltmeter Ammeter is standard Power on off switch 42 VAC 10 amp auxiliary power available for the wire feeder Circuit breaker protected 115 VAC 5 amp auxiliary power available for the wire fee...

Page 14: ...imize this effect F 42 VOLT CIRCUIT BREAKER 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 Howev...

Page 15: ...rodes 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 CV 250 GRAPHIC SYMBOL...

Page 16: ...elding gas C HIGH INDUCTANCE NEGATIVE OUTPUT CONNECTION The high inductance connection is more suit able for short arc welding heavier weldments or when using 75 Argon 25 CO2 shield ing gas This conne...

Page 17: ...rol 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...

Page 18: ...AGE 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...

Page 19: ...f 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 availab...

Page 20: ...d cover 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 HOW TO USE TROUBLESHOOTING GUIDE Service and R...

Page 21: ...ended wfs voltage settings and angle of approach of wire to work b If problem still persists call Local Lincoln Authorized Field Service Facility Allow machine to cool Be sure to provide adequate vent...

Page 22: ...between 2 4 in wire feeder receptacle 6 If welding with 1 16 aluminum wire and machine is flashing E00 1 Voltage Control misconnected 1 Open in feedback circuitry 2 Faulty PC Board 3 Voltage Adjust po...

Page 23: ...rect 1 Thermostat circuit has opened 2 Faulty Control PC Board 1 Faulty Control PC Board 2 Voltage Adjust potentiometer defective 3 Voltage Adjust potentiometer leads open 1 Defective power switch 1 P...

Page 24: ...BLEMS PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Poor arc striking with semiautomatic wire feeders Poor arc characteristics 1 Poor work connection 2 Improper pro...

Page 25: ...ontrol poten tiometer 4 Leads or connections open in control circuit 5 Faulty Control PC board 1 Local Remote switch in the wrong position 2 Faulty Local Remote switch 3 Faulty Voltage Adjust potentio...

Page 26: ...lling 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 ELECTRIC SHOCK can kill Have a qual...

Page 27: ...en 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 fu...

Page 28: ...SWITCH 76 77 75 277 276 S4 SHOWN IN LOCAL POSITION LOCAL REMOTE SWITCH R2 10K CW 376 77 377 N A WIRING VIEWED FROM REAR OF POTENTIOMETER 2 4 2 2 NC 2 L2 INPUT SUPPLY LINES S1 LINE SWITCH RECONNECT PA...

Page 29: ...LL N A WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B DIAGRAM SHOWS ELECTRODE POSITIVE TO CHANGE POLARITY TURN POWER OFF ELECTRODE CABLE 14 PIN AMPHENOL POWER SOURCE CV CV I...

Page 30: ...C SHOCK CAN KILL 6 18 93 NOT USED ON CV CV I POWER SOURCES 42 VAC 115 VAC N E POWER SOURCE FRAME CONNECTION WIRE FEEDER VOLTMETER CONNECTION CONNECTS TO WORK TERMINAL OF POWER SOURCE CONNECT TOGETHER...

Page 31: ...RSAL ADAPTER PLUG 75 76 77 GREEN N D 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 Sou...

Page 32: ...POWER SOURCE CV CV I OPTIONAL K857 TO WORK LN 25 WIRE FEEDER REMOTE CONTROL OPTIONAL K484 JUMPER PLUG REVERSE ELECTRODE AND WORK CABLES AT POWER SOURCE N C USE OF THE K857 REMOTE CONTROL REQUIRES INS...

Page 33: ...OURCE CV CV I TO WORK LN 25 WIRE FEEDER OPTIONAL K484 JUMPER PLUG OPTIONAL K864 REMOTE CONTROL ADAPTER WITH K444 1 OPTION N D N D N C N C CONNECT THE K484 JUMPER PLUG TO THE 14 PIN RECEPTACLE OF THE K...

Page 34: ...UT CONTROL OUTPUT CONTROL OUTPUT CONTROL TRIGGER CIRCUIT TRIGGER CIRCUIT SEE APPROPRIATE WIRING DIAGRAM FUNCTION FUNCTIONS ARE LISTED FOR REFERENCE ONLY AND EACH MAY OR MAY NOT BE PRESENT IN YOUR EQUI...

Page 35: ...REAR VIEW 14 PIN BOX RECEPTACLE REAR VIEW AND 14 PIN CABLE PLUG FRONT VIEW K 42 A 32 B GND C 2 L 82 D 4 E 77 M 81 F 76 G 75 N SPARE H 21 I 41 J 31 K 42 J 31 I 41 H 21 N SPARE G 75 F 76 M 81 E 77 D 4 C...

Page 36: ...IS MARKED FOR THE APPROPRIATE CABLE SIZE PER TABLE BELOW AND SKIN CABLE JACKET TO LENGTH SPECIFIED 1 INCH 25 4mm 35 50 2 mm 35 50 2 1 TWIST MATE WELDING CABLE PLUG INSTALLATION INSTRUCTIONS 9 20 91J...

Page 37: ...F 10 DIAGRAMS F 10 CV 250 CONNECTION OF NON LINCOLN WIRE FEEDERS...

Page 38: ...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 2...

Page 39: ...nd ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00...

Page 40: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 41: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 42: ...and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Pr...