Lincoln Electric V250-S Constant Current Processes, Manual ARC Welding Stick, TIG Welding

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B-4

OPERATION

B-4

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6.Arc Force - This control functions in SMAW modes to adjust the Arc Force. The arc is soft at the mini- mum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings.

RECOMMENDED ARC FORCE/INDUCTANCE SETTINGS FOR SELECTED APPLICATIONS

CONSTANT CURRENT PROCESSES

MANUAL ARC WELDING (STICK)

The Invertec may be utilized as a manual DC arc welder with the electrode cable, work cable, and elec- trode holder being the only equipment required.

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FULL RANGE IS 1-10. 1 is VERY SOFT,

10 IS VERY CRISP

 

 

Nominal

Recommended

Mode

Process

Setting

Adjustment Range

 

 

 

 

CC SMAW 1

EXX18 thru

5

1 (gentle, may stick) to 9

(soft)

EXX28 stick

 

(forceful, more spatter)

 

 

 

 

CC SMAW 2

EXX10 thru

6

3 to 10

(crisp)

EXX14 stick

 

 

 

Air Carbon Arc

1

None

 

Cutting

 

 

 

 

 

 

7.Output Terminals - These quick disconnect termi- nals provide connection points for the electrode and work cables. Refer to Output Connections in the Installation chapter for proper cable sizes. For positive polarity welding connect the electrode cable to the positive terminal and the work cable to the negative terminal. To weld negative polarity reverse the electrode and work cables.

8.Thermal Shutdown Indicator - This light will illumi- nate if an internal thermostat has been activated. Machine output will return after the internal components have returned to a normal operating temperature. See Thermal Protection later in this chapter.

AIR CARBON ARC CUTTING

Air carbon arc cutting may be performed with the Invertec within its output rating using 5/32" (3.9mm) and 3/16" (4.7mm) diameter carbon rods. Output cables, an air carbon arc electrode cable assembly, and a source of compressed air are required.

NOTE:

1.Best performance will be at settings of 200 amps and below.

2.The electronic protection circuit in the V250S will limit the current to approximately 290 amps.

TIG WELDING

The V250S is capable of touch start TIG welding. An electrode cable, work cable, Arc Start Switch or Amptrol, TIG torch, and gas supply with regulator are required. Refer to Accessories section of this manual.

Touch starting is done as follows:

1.Place the shield cup edge on the work piece.

2.Rock the tungsten down to touch.

3.Trigger the output.

4.Gently rock back the tungsten from the work- piece.

Note: The short circuit current is limited to 25 amps to aid in touch starting. Panel output control becomes the current limit setting when in remote control

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