Lincoln Electric INVERTEC V250-S User Manual

INVERTEC V250-SSERVICE MANUALSales and Service through Subsidiaries and Distributors Worldwide22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A.

A-4INSTALLATION INVERTEC V250-SA-4POWER INPUT CONNECTION FOR 50/60 HZMACHINES1. Connect terminal marked to earth groundper National Electr

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-70NOTES INVERTEC V250-SF-70Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-76NOTES INVERTEC V250-SF-76Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

A-5INSTALLATION INVERTEC V250-SA-5OUTPUT CONNECTIONSRefer to figure A.2 for the location of the 6 Pin RemoteReceptacle and the Output Terminals.FIG

F-78NOTES INVERTEC V250-SF-78Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

G-1ELECTRICAL DIAGRAMSG-1INVERTEC V250-SReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectrical Diagram Section

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

G-2ELECTRICAL DIAGRAMSINVERTEC V250SWiring Diagram (Codes 10102, 10103) ELECTRICAL SYMBOLS PER E1537H118V76CBAF757677GND REMOTE CONTROLRECEPTACLEMINT3

G-3ELECTRICAL DIAGRAMSINVERTEC V250SWiring Diagram (Codes 10187, 10188) ELECTRICAL SYMBOLS PER E1537H118V76CBAF757677GND REMOTE CONTROLRECEPTACLEMINT3

G-4ELECTRICAL DIAGRAMSINVERTEC V250SControl PC Board (G2666) LayoutITEMREQ'DPART NO. IDENTIFICATIONCAPACITORS = MFD/VOLTSRESISTORS = OHMS J2 J3

G-5ELECTRICAL DIAGRAMSINVERTEC V250SPower PC Board (G2684) LayoutCAPACITORS = MFD/VOLTSRESISTORS = OHMSITEMREQ'DPART NOIDENTIFICATION T1 B206 B2

G-6ELECTRICAL DIAGRAMSINVERTEC V250SControl PC Board (G2666) Schematic50V0.1C650V0.1C101.50KR34NCGNDSVOUTINOUTGNDVSX434751682NCGNDSVOUTINOUTGNDVSX2347

G-7ELECTRICAL DIAGRAMSINVERTEC V250SPower PC Board (G2684) Schematic325VDCE(NOMINAL)FILTER207ARECONNECTG2S2G1S1G3S4S3G4ABJ61DRIVEGATEGATEGATEGATET1657

A-6NOTES INVERTEC V250-SA-6Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCOPERATIONINVERTEC V250-SSECTION-B-1SECTION-B-1TABLE OF CONTENTS -OP

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

B-3OPERATIONB-31. Power Switch - Place the lever in the “ON” positionto energize the machine. When the power is on, thefan will operate and the output

B-4OPERATIONB-46. Arc Force - This control functions in SMAW modesto adjust the Arc Force. The arc is soft at the mini-mum settings and more forceful

B-5OPERATIONB-5PARALLEL OPERATIONThe Invertec’s are operable in parallel. For bestresults, the currents of each machine should be rea-sonably well sha

B-6NOTES INVERTEC V250-SB-6Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSECTION C-1ACCESSORIESSECTION C-1INVERTEC V250-STABLE OF CONTENTS -

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ENGINEpowered equipment.1.a. Turn the engine off before trouble

C-2ACCESSORIESC-2OPTIONS / ACCESSORIESCABLE PLUGSK852-70 - Cable Plug Kit for 1/0-2/0 cable. Attachesto welding cable to provide quick disconnect fro

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSECTION D-1MAINTENANCESECTION D-1INVERTEC V250-STABLE OF CONTENTS -

D-2MAINTENANCED-2INPUT FILTER CAPACITORDISCHARGE PROCEDURE1. Turn off input power or disconnect input powerlines.2. Remove the 5/16" hex head scr

D-3MAINTENANCED-3ROUTINE MAINTENANCE1. Perform the following preventive maintenanceprocedures at least once every six months. It isgood practice to ke

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCE-1THEORY OF OPERATIONE-1INVERTEC V250-STABLE OF CONTENTS -THEORY O

E-2THEORY OF OPERATIONE-2INPUT LINE VOLTAGEThe single-phase or three-phase input power of 208,230 or 460 volts AC is connected to the machine,through

E-3THEORY OF OPERATIONE-3PRECHARGE AND PROTECTIONThe input voltage is rectified and the DC voltage isapplied, through the reconnect switch, to the pow

E-4THEORY OF OPERATIONE-4MAIN TRANSFORMEREach IGBT pair acts as a switch assembly. Eachassembly feeds a separate, oppositely wound primarywinding of

E-5THEORY OF OPERATIONE-5OUTPUT RECTIFICATION AND CONTROLThe AC output from the main transformer secondaryis rectified to a DC output and applied to t

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCiiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filte

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINVERTEC V250-SSECTION F-1TROUBLESHOOTING & REPAIRSECTION F-1TA

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-4TROUBLESHOOTING & REPAIRF-4INVERTEC V250-SObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand

F-5TROUBLESHOOTING & REPAIRF-5INVERTEC V250-SObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand

F-6TROUBLESHOOTING & REPAIRF-6INVERTEC V250-SObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand

F-7TROUBLESHOOTING & REPAIRF-7INVERTEC V250-SObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using t

F-8TROUBLESHOOTING & REPAIRF-8INVERTEC V250-SObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand

F-9TROUBLESHOOTING & REPAIRF-9INVERTEC V250-SObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand

F-10NOTES INVERTEC V250-SF-10Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-12TROUBLESHOOTING & REPAIRF-12TEST PROCEDURE1. Remove main input power to theV250-S.2. Perform Filter Capacitor DischargeProcedure detailed in

F-13TROUBLESHOOTING & REPAIRF-137. If the correct test voltages are pre-sent the auxiliary transformer is good.8. If any of the voltages are missi

F-14NOTES INVERTEC V250-SF-14Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-16TROUBLESHOOTING & REPAIRF-16TEST PROCEDURE1. Remove main input power to theV250-S.2. Perform Filter Capacitor DischargeProceduredetailed in Ma

F-17TROUBLESHOOTING & REPAIRF-176. If the Input Rectifier does not meetthe acceptable readings outlined inTable F.2. the component may befaulty.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCivSAFETYivPRÉCAUTIONS DE SÛRETÉPourvotre propre protection lire et

F-18NOTES INVERTEC V250-SF-18Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-20TROUBLESHOOTING & REPAIRF-20TEST DESCRIPTION1. Remove main input power to theV250 -S.2. Perform Filter Capacitor DischargeProceduredetailed

F-21TROUBLESHOOTING & REPAIRF-216. If the power board does not meet theacceptable readings outlined inTable F.3. the board may be faulty.Replace.

F-22NOTES INVERTEC V250-SF-22Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-24TROUBLESHOOTING & REPAIRF-24TEST PROCEDURE1. Remove main input power to theV250-S.2. Locate the output terminals on thefront panel of the ma

F-25TROUBLESHOOTING & REPAIRF-255. If more than 200 ohms is measuredthe output diodes are not “shorted”.6. If less than 200 ohms is measured,one

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

INVERTEC V250-Svi MASTER TABLE OF CONTENTS FOR ALL SECTIONSPAGEINSTALLATION ...

F-28TROUBLESHOOTING & REPAIRF-28TEST PROCEDURE1. Remove main input power to theV250-S.2. Perform Filter Capacitor DischargeProceduredetailed in

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-30NOTES INVERTEC V250-SF-30Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-34NOTES INVERTEC V250-SF-34Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-36TROUBLESHOOTING & REPAIRF-36TEST PROCEDURE1. Remove main input power to theV250-S.2. Perform Filter Capacitor DischargeProceduredetailed in

F-37TROUBLESHOOTING & REPAIRF-374. The following tests will be performedwith the input power applied to theV250-S. BE CAREFUL. ALWAYSREMOVE INP

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSECTION-A-1INSTALLATION INVERTEC V250-SSECTION-A-1TABLE OF CONTEN

F-38NOTES INVERTEC V250-SF-38Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-40TROUBLESHOOTING & REPAIRF-40TEST PROCEDURE1. Remove main input power to theV250-S.2. Perform Filter Capacitor DischargeProceduredetailed in

F-41TROUBLESHOOTING & REPAIRF-418. Check for the appropriate voltagesoutlined in Table F.6. Note:Voltages may vary with the inputline voltage.

F-42NOTES INVERTEC V250-SF-42Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-44TROUBLESHOOTING & REPAIRF-44PROCEDURE1. Remove input power to the V250-S.2. Perform Filter Capacitor DischargeProceduredetailed in Maintenan

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-46TROUBLESHOOTING & REPAIRF-46PROCEDURE1. Remove input power to the V250-S.2. Perform Filter Capacitor DischargeProceduredetailed in Maintenan

F-47TROUBLESHOOTING & REPAIRF-477. Using the 1/4” nut-driver remove thetwo screws holding the P.C. board tothe heat sink mounting bracket.8. Wit

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-48NOTES INVERTEC V250-SF-48Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-50TROUBLESHOOTING & REPAIRF-50PROCEDURE1. Remove input power to the V250-S.2. Perform Filter Capacitor DischargeProceduredetailed in Maintenan

F-51TROUBLESHOOTING & REPAIRF-517. Once the top of the bracket assem-bly is disengaged from the top centerpanel the bracket assembly can beremove

F-52NOTES INVERTEC V250-SF-52Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-54TROUBLESHOOTING & REPAIRF-54PROCEDURE1. Remove input power to the V250-S.2. PerformFilter Capacitor DischargeProceduredetailed in Maintenanc

F-55TROUBLESHOOTING & REPAIRF-557. Carefully remove the input rectifierbridge.8. When installing a new input rectifierapply a thin coating of Do

F-56NOTES INVERTEC V250-SF-56Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

A-3INSTALLATION INVERTEC V250-SA-3Read this entire installation section before youstart installation.SAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Hav

F-58TROUBLESHOOTING & REPAIRF-58PROCEDURE1. Remove input power to the V250-S.2. Perform Filter Capacitor DischargeProceduredetailed in Maintenan

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-60NOTES INVERTEC V250-SF-60Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

F-64NOTES INVERTEC V250-SF-64Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to M

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC