Lincoln Electric V250-S service manual Power PC Board G2684 Layout, Power P.C. BD. Asbly

Page 116

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G-5

ELECTRICAL DIAGRAMS

G-5

Power PC Board (G2684) Layout

 

 

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G2684

 

POWER P.C. BD. AS'BLY

 

 

 

 

 

 

 

B201

B204

 

 

 

 

 

 

 

 

 

 

 

B209

 

B208

 

B205

 

 

 

 

 

 

 

 

 

 

 

 

 

J6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D7

 

 

 

 

 

 

 

 

 

 

R78

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R61

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

OCI2

 

 

 

 

 

 

 

 

CR1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T1

 

R50

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R51

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R72

 

 

 

 

 

R57

R60

R58

R59

 

 

 

 

 

 

 

 

 

 

 

D4

 

 

 

 

 

 

 

 

 

 

 

 

R55

 

 

R53

R52

 

 

 

 

 

 

 

 

 

 

R10

 

 

 

R73

D3

D5

C3

 

 

X2

 

R13

 

 

R11

 

 

 

R74

 

 

 

 

R56

 

 

 

 

R40

 

 

 

 

 

 

 

 

 

 

 

 

R35

 

 

 

 

D2

 

 

 

 

 

 

 

 

R71

 

 

 

 

C7

 

 

 

 

 

R12

 

 

 

 

DZ15

R77

C9

 

 

 

R18

R34

R36

R39

R75

X1

R15

R14

R27

 

 

R26

R47

 

 

 

R37

 

C6

 

 

R31

 

 

 

 

 

 

 

 

 

 

 

 

 

R76

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R16

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C4

 

 

 

 

 

 

 

 

R48

 

 

 

 

 

 

 

OCI1

 

R19

 

 

R32

 

 

 

 

 

 

 

 

 

 

 

 

 

R17

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DZ4

 

 

 

 

 

 

 

 

 

D10

 

 

 

 

 

 

 

 

 

Q1

 

D9

 

 

 

 

 

 

B207A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B203A

 

 

 

 

 

 

 

 

 

 

 

 

DZ11

 

DZ5

 

 

 

 

 

 

 

 

 

A2

 

 

 

 

 

R45

 

 

R20

 

A1

 

 

 

 

 

 

 

 

 

 

 

 

R44

 

 

R25

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R43

 

 

DZ6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R42

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C8

 

 

C5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DZ10

 

 

R24

 

 

 

 

 

 

 

 

 

D11

 

 

 

 

 

 

 

R23

 

D8

 

 

 

G2684

 

 

 

 

 

 

 

 

R46

 

 

R22

 

 

 

 

 

 

B202A

 

 

 

 

 

 

R41

 

 

R21

 

 

 

B206

 

 

 

 

 

 

 

 

 

 

 

DZ9

 

 

DZ7

 

 

 

 

 

 

 

 

 

C12

 

 

 

 

 

DZ14

 

DZ1

 

C2

 

 

 

V25OS

 

 

 

 

 

 

 

 

R66

 

 

R1

 

 

 

 

 

 

 

 

 

 

 

 

 

R65

 

 

R6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R64

 

 

DZ2

 

 

 

 

 

 

 

 

R68

R69

 

 

 

 

 

R63

 

 

 

 

R7

R8

R29

R30

POWER

 

 

 

 

 

 

 

 

C11

 

C1

 

 

 

 

 

 

 

 

 

 

DZ13

 

 

R5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R67

 

 

R3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R62

 

 

R2

 

 

 

 

 

 

DZ12DZ3

ITEM

REQ'D PART NO

IDENTIFICATION

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CAPACITORS = MFD/VOLTS

RESISTORS = OHMS

NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not

available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result INVERTEC V250S in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.

Image 116
Contents Invertec V250-S Safety Fumes and Gases can be dangerous Electric Shock can killARC Rays can burn 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 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 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 WeldingThermal Protection Parallel OperationOverload Protection Invertec V250-S Accessories Table of Contents Accessories SectionCable Plugs Options / AccessoriesRemote Controls 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 Maximum Output Pulse Width ModulationMinimum 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 Materials Needed Auxiliary Transformer TestTest Description 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 BoardTest Conditions Table F.4. Power Board Voltage Test PointsAcceptable Test Description 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 V250S Control Control Board Removal and ReplacementProcedure 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