Lincoln Electric V250-S service manual Figure F.22 Main Transformer Mountings

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F-68

TROUBLESHOOTING & REPAIR

F-68

 

 

MAIN TRANSFORMER REMOVAL AND REPLACEMENT

(MACHINE CODES BELOW 10150)

(continued)

MAIN TRANSFORMER

LOCKING MOUNTING TABS

MAIN TRANSFORMER

MOUNTING SCREWS

Figure F.22 Main Transformer Mountings

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14.Using the slot head screwdriver unclip the locking tabs and slide the transformer towards the front of the machine until it is free of the slots in the bottom of the machine.

Note: The machine will have to be tilted on its side to gain access to the bottom of the unit.

15.With the main transformer loose from the base carefully tilt and remove the transformer from the left side of the machine.

16.Install the new transformer by tilting and carefully positioning it in place in the slots in the case bottom. Slide towards the rear of the machine until the locking tabs are in place.

17.With the 3/8” wrench replace the two transformer mounting screws.

Note: The machine will have to be tilted on its side to gain access to the bottom of the unit.

18.Using the 7/16” wrench reassemble the two secondary leads to the out- put rectifier leads. Note lead and washer placement and lead labels.

19.Using the slot head screwdriver and 3/8” nut-driver reassemble the two reactor leads to the output rec- tifier leads. Note lead labels.

20.Replace the sleeving on the four connections and replace the cable ties.

21.With the 3/4” wrench assemble the two secondary leads to the positive output terminal.

Take note of the by-pass connec- tion on the positive output terminal.

INVERTEC V250-S

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Contents Invertec V250-S Safety ARC Rays can burn Electric Shock can killFumes and Gases can be dangerous Cylinder may explode if damaged Welding Sparks can cause fire or explosionPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Installation Table of Contents Installation SectionThree 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 Remote Control Receptacle Output ConnectionsQuick Disconnect Plugs Output CablesInvertec V250-S Operation Safety Instructions Gouging SparksControls and Settings Figure B.1 Case Front ControlsConstant Current Processes Manual ARC Welding StickAIR Carbon ARC Cutting TIG WeldingOverload Protection Parallel OperationThermal Protection Invertec V250-S Accessories Table of Contents Accessories SectionRemote Controls Options / AccessoriesCable Plugs Maintenance Table of Contents Maintenance SectionInput Filter Capacitor Discharge Procedure Figure D.1 Location of Input Filter Capacitor TerminalsRoutine Maintenance Filter Capacitor ConditioningFigure D.2 Location of Maintenance Components Table of Contents Theory of Operation Section Theory of OperationGeneral Description Input Line VoltagePrecharge and Protection Figure E.2 Protection and PRE-CHARGE CircuitsMain Transformer Figure E.3 Main TransformerOutput Rectification Control Figure E.4 Output Rectification and ControlProtection Circuits Overload ProtectionInsulated Gate Bipolar Transistor Igbt Operation Minimum Output Pulse Width ModulationMaximum Output Troubleshooting & Repair HOW to USE Troubleshooting Guide Oscilloscope WarningPC Board Troubleshooting Procedures Board can be dam- aged by static electricityPossible Areas Recommended Symptoms Course of ActionPossible Areas Perform the Control Board Voltage ChecksCapacitor Balance Test Troubleshooting & Repair Perform the Output Diode Test Welding Problems Invertec V250-S Test Description Auxiliary Transformer TestMaterials Needed Test Procedure Auxiliary Transformer TestAuxiliary Transformer Test Table F.1 Auxiliary Transformer Test PointsInvertec V250-S Input Rectifier Test Test Procedure Input Rectifier TestTable F.2 Input Rectifier Test Points Test Point Terminals Analog Meter X10 RangeInvertec V250-S Power Board Resistance Test Power Board Resistance Test Test DescriptionPower Board Resistance Test Table F.3 Power Board Resistance Test PointsInvertec V250-S Output Diodes Test Output Diodes Test Figure F.4 Machine Output TerminalsInvertec V250-S Diode Modules Power Board Voltage Test Power Board Voltage Test Figure F.8 Plug J6 on Power BoardAcceptable Test Description Table F.4. Power Board Voltage Test PointsTest Conditions Invertec V250-S Control Board Voltage Test Control Board Voltage Test Figure F.9 Plugs J1-J5 on Control BoardTable F.5. Control Board Voltage Test Points 18VACInvertec V250-S Protection Circuit Test Protection Circuit Test Figure F.10 Control Board Plug J2 Test PointsProtection Circuit Simplified Invertec V250-S Capacitor Balance Test Figure F.12 Power Board and Capacitor Test Locations Capacitor Balance TestTable F.6 Capacitor Voltages Invertec V250-S Control Board Removal and Replacement Procedure Control Board Removal and ReplacementV250S Control Power Board Removal and Replacement Power Board Removal and Replacement Figure F.14 Power Board Lead LocationsPower Board Replacement Procedure Invertec V250-S Filter Capacitor Removal and Replacement Matched PartsFilter Capacitor Removal and Replacement Figure F.15 Heatsink/Power Board RemovalPerform Power Board Replacement Procedure in this section Invertec V250-S Input Rectifier Bridge Removal and Replacement Input Rectifier Bridge Removal and Replacement Figure F.16 Input Rectifier Lead LocationsTroubleshooting & 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 Maximum Acceptable Output AT Minimum Output Settings Minimum Acceptable Output AT Maximum Output SettingsRetest After Repair Input Idle Amps and Idle WattsInvertec V250-S Electrical Diagrams Invertec V250-S Wiring Diagram Codes 10102 Invertec V250SWiring Diagram Codes 10187 Return to SectionControl PC Board G2666 Layout G2666Power PC Board G2684 Layout Power P.C. BD. AsblyControl PC Board G2666 Schematic Relay CoilsPower PC Board G2684 Schematic From Control BD