Lincoln Electric V250-S service manual Wiring Diagram Codes 10102, Invertec V250S

Page 113

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TOC

G-2

ELECTRICAL DIAGRAMS

G-2

Wiring Diagram (Codes 10102, 10103)

 

 

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TOC

N.C.

S4

 

206

202

 

PRIMARY

207

203A

RECONNECT

203

 

SWITCH

202A

 

203

 

 

 

202

 

 

 

 

 

 

S1

 

 

 

 

POWER

 

 

 

OFF ON

 

 

A

W

U

 

H1

 

 

 

 

TP1

 

H1

 

R

 

 

 

B

 

206

 

 

C1

 

 

1600/450

 

203A

 

202A

 

207

C2

 

1600/450

 

 

F

-

207A

D9

 

 

 

INPUT

 

 

+

206 204

-

203A 201

POWER 205 BOARD

+

202A

-

207A

208

1

2

204

I

201

205

Y Y I

T3

CURRENT

TRANSFORMER

208

308

307

204F

BACK OUTSIDE

S

S

FRONT

INSIDE

201F

205F

FRONT OUTSIDE

S

S

BACK

INSIDE

208F

L2 RIGHT

 

 

 

D8

S

F

 

C4

F

 

10

R2

BACK

2W

.001/400

 

 

 

S

AUX.

 

 

 

 

 

F

 

 

 

 

BACK

 

D5, D6, D7

SF

 

 

 

 

 

F

 

 

 

S

 

 

 

 

FRONT

 

 

F

 

 

 

S FRONT

 

D2, D3, D4

 

AUX.

 

.001/400

F

 

 

 

10

R1

 

 

2W

S

F

C3

 

L1 LEFT

 

D1

 

 

 

 

 

 

 

TP5

 

 

TP6

 

 

 

 

 

 

 

 

TP4

 

 

 

315

B W

 

 

 

316

 

309

1

 

J4

2

W

310

6

 

1

B

 

 

307

7

 

 

 

 

308

4

J2

 

1

375

311

2

 

2

377

 

 

313

8

 

 

3

324

Y

3

 

 

 

 

4

376

+ ARC

C5

229

C6

- ARC

304

 

2

CC SOFT

 

 

 

 

1

 

 

S2

303

 

 

 

CC GTAW

MODE

303A

 

 

 

 

 

SWITCH

305

 

 

 

 

3

CC CRISP

 

 

 

 

 

 

303A

 

REMOTE

 

S3

330

 

LOCAL

 

LOCAL/REMOTE

 

 

 

SWITCH

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INPUT

V

 

PER

 

TP2

TP3

N.A.

B

C

 

 

W

A

 

G

 

 

 

A

 

0.6 AMP

H1

 

 

 

SLOW

H3

 

BLOW

A

BRIDGE

 

 

D

+

209

 

 

FAN

MOTORS

J7

H1 1 H1

3

J6 4

5

2096

310

311

313

309

T1

MAIN

TRANSFORMER

315

317

R6

100

R R 5W R R

Y

5

 

 

5

330

 

 

 

 

6

321

316

2

 

J3

7

303

 

8

305

317

4

 

 

J1

 

9

304

3

 

R

 

 

10

327

R

1

 

 

 

 

11

328

 

 

 

 

 

CONTROL

 

12

229

 

 

13

319

 

BOARD

J5

14

 

 

 

 

 

 

14 2 5 6 3

322 318 75 76 77

377

 

CW (MAX)

R3

 

 

 

376

R3

10K

OUTPUT

2W

CONTROL

 

 

375

 

 

 

375B

 

 

 

327

 

CW (MAX)

R4

 

 

 

328

R4

10K

ARC FORCE

2W

/INDUCTANCE

 

 

 

 

 

CONTROL

324

 

CW (MAX)

R5

 

 

 

 

 

50K

STRIKE ENERGY

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Master TOC

 

200-

H2

4

H2

 

 

 

 

 

 

 

 

R

 

208V

H3

 

H3

 

220-

H3

2

18V

 

 

R

 

 

 

 

 

230V

 

 

 

 

 

 

H4

 

 

380-

H4

3

 

 

 

 

 

 

 

 

 

 

415V

 

 

H5

 

A

440-

H5

6

 

 

 

 

 

5

 

 

 

460V

 

 

T2

N.C.

 

 

 

 

 

 

AUXILIARY

 

 

 

 

TRANSFORMER

NOTES:

N.A.

1. FOR MACHINES SUPPLIED WITH INPUT CABLE

FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE. CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE

FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.

FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONNECTION SHOWN IS FOR 440-460V OPERATION.

N.D. D2 THRU D4 OUTPUT DIODES ARE A MATCHED SET.

D5 THRU D7 OUTPUT DIODES ARE A MATCHED SET.

N.E. C1, C2 CAPACITORS ARE A MATCHED SET.

J4

J1

J5, J6, J7

J2

J3

CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD)

COLOR CODE:

B = BLACK

G = GREEN

R = RED

W = WHITE

Y = YELLOW

R5

2W

CONTROL

 

375B

 

 

321

 

+

 

THERMAL

 

 

 

 

 

Y

 

 

OVERLOAD

 

 

 

INDICATOR

 

 

 

 

319

 

 

 

 

322

D

 

2

GTAW (REMOTE)

318

E

MIN

4

TRIGGER

75

C

 

 

75

 

REMOTE

 

 

 

 

76

B

76

 

OUTPUT

 

CONTROL

77

A

77

 

 

 

G F GND

REMOTE

CONTROL

RECEPTACLE

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ELECTRICAL SYMBOLS PER E1537

 

 

 

8-5-94

 

 

 

 

 

 

 

 

CLEVELAND, OHIO U . S . A .

L9280

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

INVERTEC V250S

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Page 112 Page 114
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 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 WeldingThermal 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 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
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