Lincoln Electric V250-S Output Connections, Quick Disconnect Plugs, Remote Control Receptacle

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A-5	INSTALLATION	A-5
OUTPUT CONNECTIONS	QUICK DISCONNECT PLUGS

Refer to figure A.2 for the location of the 6 Pin Remote	A quick disconnect system is used for the welding
Receptacle and the Output Terminals.	cable connections. The welding plug included with the
	machine is designed to accept a welding cable size of
	1/0 to 2/0.

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6PIN REMOTE RECEPTACLE

SMAW

GTAW SMAW

THERMAL

SOFT

CRISP

HOT START

					5	6
					4	7
					3	8
		A		120	2	8
		A	85		2
		OUTPUT	85		1	9
		OUTPUT			1	9
		50		170	0	10
				170		10

		15		230	ARC FORCE
	REMOTE	LOCAL	1	230	5	6
	REMOTE	LOCAL			5	6
					4	7
					3	7
				250	3	8
				250	2	8
					2
					1	9
					0	10
						10
		INVERTEC ¤ V250-S

						S
	-		+		I

O

1.Remove 1 in. (25mm) of welding cable insulation.

2.Slide rubber boot onto cable end. The boot end may be trimmed to match the cable diameter. Soap or other lubricant will help to slide the boot over the cable.

BOOT

WELDING CABLE

25 mm

TRIM

1 in.

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OUTPUT TERMINALS

FIGURE A.2 OUTPUT CONNECTIONS

REMOTE CONTROL RECEPTACLE

Remote control (K857), Arc start switch (K814), Hand amptrol (K963) and Foot amptrol (K870) connect directly to 6 pin amphenol on the front of the unit.

3.Slide the copper tube into the brass plug.

4.Insert cable into copper tube.

5.Tighten set screw to collapse copper tube. Screw must apply pressure against welding cable. The top of the set screw will be well below the surface of the brass plug after tightening.

SET SCREW

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OUTPUT CABLES

Select the output cable size based on Table A.1.

TABLE A.1

Cable Sizes for Combined Length of Electrode and

Work Cable ( Copper Cable Rated at 75°C).

Length	Cable Size
up to 150 ft.(46m)	1/0 (50mm2)
up to 250 ft.(72m)	2/0 (70mm2)

BRASS PLUG

COPPER TUBE

6.Slide rubber boot over brass plug. The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle.

INVERTEC V250-S

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Contents Invertec V250-S Safety Fumes and Gases can be dangerous Electric Shock can killARC Rays can burn 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 Technical Specifications Invertec V250-SThree Phase Single Phase Select Suitable Location Safety PrecautionsInput Connections Power Input Connection for 50/60 HZ Machines Input Voltage Reconnect ProcedureInput Fuse and Supply Wire Output Cables Remote Control ReceptacleOutput Connections Quick Disconnect PlugsInvertec V250-S Operation Gouging Sparks Safety InstructionsFigure B.1 Case Front Controls Controls and SettingsTIG Welding Constant Current ProcessesManual ARC Welding Stick AIR Carbon ARC CuttingThermal Protection Parallel OperationOverload Protection Invertec V250-S Table of Contents Accessories Section AccessoriesCable Plugs Options / AccessoriesRemote Controls 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 Maximum Output Pulse Width ModulationMinimum 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 Materials Needed Auxiliary Transformer TestTest Description 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 TestTest Conditions Table F.4. Power Board Voltage Test PointsAcceptable Test Description 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 V250S Control Control Board Removal and ReplacementProcedure 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 Input Idle Amps and Idle Watts Maximum Acceptable Output AT Minimum Output SettingsMinimum Acceptable Output AT Maximum Output Settings Retest After RepairInvertec 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