Lincoln Electric service manual Invertec V250-S

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SVM124-A

INVERTEC V250-S	July, 1996
	July, 1996

For use with machine Code Numbers 10102 to 10188

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 MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL

World's Leader in Welding and Cutting Products

Premier Manufacturer of Industrial Motors

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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Contents Invertec V250-S Safety ARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Welding Sparks can cause fire or explosion Cylinder may explode if damagedSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section InstallationThree Phase Single Phase Technical Specifications Invertec V250-SThree Phase Input Connections Safety PrecautionsSelect Suitable Location Input Fuse and Supply Wire Input Voltage Reconnect ProcedurePower Input Connection for 50/60 HZ Machines Output Connections Remote Control ReceptacleQuick Disconnect Plugs Output CablesInvertec V250-S Operation Gouging Sparks Safety InstructionsFigure B.1 Case Front Controls Controls and SettingsManual ARC Welding Stick Constant Current ProcessesAIR Carbon ARC Cutting TIG WeldingOverload Protection Parallel OperationThermal Protection Invertec V250-S Table of Contents Accessories Section AccessoriesRemote Controls Options / AccessoriesCable Plugs Table of Contents Maintenance Section MaintenanceFigure D.1 Location of Input Filter Capacitor Terminals Input Filter Capacitor Discharge ProcedureFilter Capacitor Conditioning Routine MaintenanceFigure D.2 Location of Maintenance Components Theory of Operation Table of Contents Theory of Operation SectionInput Line Voltage General DescriptionFigure E.2 Protection and PRE-CHARGE Circuits Precharge and ProtectionFigure E.3 Main Transformer Main TransformerFigure E.4 Output Rectification and Control Output Rectification ControlOverload Protection Protection CircuitsInsulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationMaximum Output Troubleshooting & Repair Oscilloscope Warning HOW to USE Troubleshooting GuideBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresCourse of Action Possible Areas Recommended SymptomsPerform the Control Board Voltage Checks Possible AreasCapacitor Balance Test Troubleshooting & Repair Perform the Output Diode Test Welding Problems Invertec V250-S Test Description Auxiliary Transformer TestMaterials Needed Auxiliary Transformer Test Test ProcedureTable F.1 Auxiliary Transformer Test Points Auxiliary Transformer TestInvertec V250-S Input Rectifier Test Input Rectifier Test Test ProcedureTest Point Terminals Analog Meter X10 Range Table F.2 Input Rectifier Test PointsInvertec V250-S Power Board Resistance Test Test Description Power Board Resistance TestTable F.3 Power Board Resistance Test Points Power Board Resistance TestInvertec V250-S Output Diodes Test Figure F.4 Machine Output Terminals Output Diodes TestInvertec V250-S Diode Modules Power Board Voltage Test Figure F.8 Plug J6 on Power Board Power Board Voltage TestAcceptable Test Description Table F.4. Power Board Voltage Test PointsTest Conditions Invertec V250-S Control Board Voltage Test Figure F.9 Plugs J1-J5 on Control Board Control Board Voltage Test18VAC Table F.5. Control Board Voltage Test PointsInvertec V250-S Protection Circuit Test Figure F.10 Control Board Plug J2 Test Points Protection Circuit TestProtection Circuit Simplified Invertec V250-S Capacitor Balance Test Capacitor Balance Test Figure F.12 Power Board and Capacitor Test LocationsTable F.6 Capacitor Voltages Invertec V250-S Control Board Removal and Replacement Procedure Control Board Removal and ReplacementV250S Control Power Board Removal and Replacement Figure F.14 Power Board Lead Locations Power Board Removal and ReplacementPower Board Replacement Procedure Invertec V250-S Matched Parts Filter Capacitor Removal and ReplacementFigure F.15 Heatsink/Power Board Removal Filter Capacitor Removal and ReplacementPerform Power Board Replacement Procedure in this section Invertec V250-S Input Rectifier Bridge Removal and Replacement Figure F.16 Input Rectifier Lead Locations Input Rectifier Bridge Removal and ReplacementTroubleshooting & Repair Invertec V250-S Materials Needed Snubber Resistors Locking Tabs Invertec V250-S Wrench Allen type wrench Torque wrench Mounting Bolts Diode Modules Bolted Connections Troubleshooting & Repair Invertec V250-S Main Transformer Removal and Replacement Machine Codes below T3 Current Transformer Main Transformer Main Transformer Secondary Leads Figure F.22 Main Transformer Mountings Clear all leads and secure for case wrap-around assembly Invertec V250-S Main Transformer Removal and Replacement Machine Codes Above Figure F.23 Main Transformer Right Side Figure F.24 Main Transformer Left Side Figure F.25 Main Transformer Mountings Troubleshooting & Repair Invertec V250-S Minimum Acceptable Output AT Maximum Output Settings Maximum Acceptable Output AT Minimum Output SettingsRetest After Repair Input Idle Amps and Idle WattsInvertec V250-S Electrical Diagrams Invertec V250-S Invertec V250S Wiring Diagram Codes 10102Return to Section Wiring Diagram Codes 10187G2666 Control PC Board G2666 LayoutPower P.C. BD. Asbly Power PC Board G2684 LayoutRelay Coils Control PC Board G2666 SchematicFrom Control BD Power PC Board G2684 Schematic