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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.

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.

iii

SAFETY

iii

Mar ‘95

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.
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.

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 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).

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.

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.

6.h. Also see item 1.c.

Содержание IDEALARC CV-250

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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