Lincoln Electric IM505 User Manual

IDEALARC CV-250

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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 thought­ful 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.

®

For use with machine Code Numbers 10013, 10014

IM505

December, 1999

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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
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.

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.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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.

ARC RAYS can burn.

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 skin and that of your helpers from
the arc rays.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and 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.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.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

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.

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.

5.e. Also see item 1.b.

Mar ‘95

vapors

to

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc­tions 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 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.

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.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er 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.

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.

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.

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 lev­age, 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.

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 forte­ment toxique) ou autres produits irritants.

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 pro­téger 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.

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.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma­bles.

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.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.

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. Garder tous les couvercles et dispositifs de sûreté à leur

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to 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.

vv

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.

TABLE OF CONTENTS

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

vi

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

Diagrams ..........................................................................................................Section F

Parts Manual....................................................................................................Appendix

....................E-8

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS – IDEALARC CV-250

INPUT - THREE PHASE ONLY

Standard

Voltage

208/230/460/3/60

Input Current at

Rated Output

100% Duty Cycle 56/51/26

60% Duty Cycle 62/56/28

A-1

Code

Number

10013

230/460/575/3/60

Duty Cycle

100% Duty Cycle

NEMA Class I (100)

60% Duty Cycle

100% Duty Cycle

Welding Current/Voltage Range

(Continuous)

30A/7V - 300A/32V

DC

Efficiency at 100% Load

72%

Idle Power

800W

100% Duty Cycle 51/26/20

60% Duty Cycle 56/28/22

RATED OUTPUT

Amps

250

300
250

OUTPUT

Normal Open Circuit Voltage

10-43

MAX OCV: 50

MISC. INFORMATION

Input kVA

60% Load - 22.3

100% Load - 20.3

Power Factor at 100% Load

.53

10014

Volts at Rated Amperes

30

32
30

Auxiliary

42 Volts AC, 10 Amps
115 Volts AC, 5 Amps

( Both Circuit Breaker Protected)

Idle Current - Amps

Power

11/10/5

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 686 mm

(Lift bail, add 80 mm)

CV-250

A-2

INSTALLATION

A-2

Read entire installation section before starting
installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Only qualified personnel should
perform this installation.

• Turn the input power OFF at the discon­nect switch or fuse box before working on
this equipment.

• Turn the Power switch on the CV-250
“OFF” before connecting or disconnect­ing output cables, wire feeder or remote
connections, or other equipment.

• Do not touch electrically hot parts.

• Always connect the Idealarc CV-250
grounding terminal (located on the welder
base near the reconnect panel) to a good
electrical earth ground.

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.

STACKING

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.

TILTING

Do not place the machine on a surface that is inclined
enough to create a risk of the machine falling over.

INPUT CONNECTIONS

Be sure the voltage, phase, and frequency of the input
power is as specified on the welder nameplate.

Gain access to the input reconnect panel by removing
the right case side of the CV-250 (side nearest to the
Power switch.)

Have a qualified electrician connect the input leads to
L1, L2, and L3 of the input reconnect panel in accor­dance 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.

The frame of the welder must be grounded. A ground
terminal marked with the symbol located on the
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.
"Delay type"
fuses. Using fuses or circuit breakers smaller than
recommended may result in "nuisance" tripping from
welder inrush currents even if not welding at high cur­rents.

RECOMMENDED INPUT WIRE AND FUSE SIZES

Input

Voltage /

Frequency

208/60

230/60

460/60

575/60

200/50/60

220/50/60

230/50/60

380/50/60

400/50/60

415/50/60

440/50/60

500/50/60

1

circuit breakers may be used in place of

Fuse

(Super Lag)

or Breaker

Size

90

80

40

30

90

80

80

50

45

45

45

40

Input

Ampere

Rating on

Nameplate

56

51

26

20

59

54

52

31

30

29

27

24

Type 75°C

Copper Wire in

Conduit AWG

(IEC) Sizes

6 (16mm2)

6 (16mm2)

10 (6mm2)

10 (6mm2)

4 (25 mm2)

6 (16mm2)

6 (16mm2)

8 (10mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

Type 75°C

Copper

Ground Wire in

Conduit AWG

(IEC) Sizes

8 (10mm2)

8 (10mm2)

10 (6mm2)

10 (6mm2)

8 (10mm2)

8 (10mm2)

8 (10mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

10 (6mm2)

CV-250

1

Also called “inverse time” or “thermal/magnetic” circuit breakers; circuit
breakers which have a delay in tripping action that decreases as the magni­tude of the current increases.

A-3

INSTALLATION

A-3

FIELD INSTALLED 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 EQUIPMENT-CONTROL
CABLE CONNECTIONS

Follow the instructions below which are appropriate
for the wire feeder that will be used.

LN-7 to CV-250

a) Turn the CV-250 Power switch to the "OFF" posi-

tion.

b) Connect the LN-7 control cable to the wire feeder

receptacle on the CV-250.

c) See OUTPUT CONNECTIONS for connection of

work and electrode cables.

LN-25 to CV-250

a) Turn the CV-250 Power switch to the "OFF" posi-

tion.

b) Plug a K484 jumper plug into the CV-250 wire

feeder receptacle.

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 the K857.

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.

OUTPUT CONNECTIONS

Output cables must have Magnum Twist-Mate™ plugs
for connection to the CV-250. Order K852-70 for con­necting 1/0-2/0 (50-70 mm2) cables. Refer to S18737
for instructions on installing these plugs.

Use the shortest possible cable lengths. See Table
A.1 for recommended cable sizes based on length.

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

" ").

TABLE A.1

Cable Sizes for Combined Lengths of Copper

Electrode and Work Cable

Machine Size

250 A 100%
(300 A 60%)

Lengths up to

150 ft 150 to 200 ft

1/0 (50mm2) 2/0 (95mm

2

)

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

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 recep­tacle. 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 conve­nience, wire feeder connection details are shown in
the DIAGRAM section.

A-4

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 con­trol and power connections between the CV­250 and the wire feeder WITHOUT the need
for a K867 Universal Adapter.

CV-250

B-1

OPERATION

OPERATING INSTRUCTIONS

Read and understand this entire section before oper­ating 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.

B-1

• 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

B-2

OPERATION

CAUTION

When using a CV-250 power source with wire feed­ers, there will be a small spark if the electrode con­tacts 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 ground
during these several seconds.

------------------------------------------------------------------------

B-2

• Circuit breaker protected.

• 115 VAC, 5 amp auxiliary power available for the
wire feeder; circuit breaker protected.

• 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.

DESIGN FEATURES

GENERAL DESCRIPTION

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.

It is available from the factory in one model only, with
no options other than input voltage or frequency.

RECOMMENDED PROCESSES AND
EQUIPMENT

The CV-250 is capable of solid wire welding within the
rated output capacity of the machine. It is also capa­ble of welding with the following flux-cored wires: NR­152, NR-211, NS-3M, NR-203 Ni 1%, and
Outershield® 70 and 71.

The CV-250 is recommended for use with the LN-7,
LN-742 and LN-25 wire feeder models.

• "Clean" appearance and simple controls -- easy to

operate.

• Electronic and thermostatic protection from over­loads.

• Submersion dipping of assembled transformer,
choke, and rectifier in special sealing/insulating
material gives extra protection against moisture and
corrosive atmospheres.

• Microprocessor based Control PC Board has built-in
diagnostic routines.

• Compact size, requires only 19" x 26" footprint.

• Modular construction for easy servicing.

• Recessed panels protect output studs and controls.
Large safety margins and protective circuits protect
rectifiers from transient voltages and high currents.

LIMITATIONS

OPERATIONAL FEATURES AND
CONTROLS

• Two inductance positions: operator can choose the
optimum output characteristics.

• Solid State Output Contactor: no noise, no moving
parts to wear.

• Digital Voltmeter/Ammeter is standard.

• Power on/off switch.

• 42 VAC, 10 amp auxiliary power available for the
wire feeder.

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.

POWER SOURCE OPERATION

Be sure the CV-250 is properly installed, and that all
accessories are properly hooked up before attempting
operation.

DUTY CYCLE

250 Amps, 30 Volts at 100%
300 Amps, 32 Volts at 60%

Duty Cycle is based on operation for a 10 minute period.

CV-250