Lincoln Electric V250-S service manual General Description, Input Line Voltage

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E-2

THEORY OF OPERATION

E-2

 

 

 

 

 

GENERAL DESCRIPTION

The Invertec V250-S is a 250 amp arc welding power source that utilizes either single or three phase input power to produce a constant current output. The output response of this machine has been optimized for the SMAW and TIG welding processes.

FIGURE E.1 - INPUT VOLTAGE CIRCUITS

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INPUT

INPUTRECTIFIER LINE

SWITCH

"A"

L

E

A

D

FAN

MOTORS

R

E

C

O

N

N

E

C

T

S

W

I

T

C

H

18VAC

POWER BOARD

MAIN

 

TRANSFORMER

 

 

 

 

CR1

 

 

 

RELAY

 

 

 

IGBT

 

 

 

 

 

 

POSITIVE

CAPACITOR

 

 

OUTPUT

 

 

 

TERMINAL

IGBT

 

 

 

IGBT

 

SHUNT

 

 

 

 

 

CURRENT

 

 

 

TRANSFORMER

 

NEGATIVE

 

 

 

CAPACITOR

 

F

OUTPUT

 

 

TERMINAL

 

 

E

F

IGBT

 

E

E

 

 

D

E

 

 

B

D

 

 

A

B

 

 

C

A

O

 

K

C

V

 

 

E

 

THERMOSTATS

K

R

 

 

V

 

 

 

O

 

 

 

L

 

 

 

T

IGBT GATE SIGNALS

THERMAL

A

G

 

 

E

PROTECTION SIGNAL

CONTROL BOARD

LIGHT

 

CR1 RELAY DRIVE SIGNAL

 

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AUXILIARY

TRANSFORMER

REMOTE

RECEPTACLE

OUTPUT STRIKE ARC

 

 

 

LOCAL/

 

MODE

 

REMOTE

CONTROL CONTROL FORCE

SWITCH

CONTROL

 

 

 

SWITCH

 

 

 

 

INPUT LINE VOLTAGE

The single-phase or three-phase input power of 208, 230 or 460 volts AC is connected to the machine, through a line switch located on the front panel.

A reconnect panel and switch allows the user to con- figure the machine for either a low or high input volt- age and also connect the auxiliary transformer for the appropriate input voltage.

The auxiliary transformer develops the appropriate AC voltages to operate the cooling fans and the control board.

NOTE: Unshaded areas of block logic diagrams are the subject of discussion.

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 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 Quick Disconnect Plugs Remote Control ReceptacleOutput Connections Output CablesInvertec V250-S Operation Safety Instructions Gouging SparksControls and Settings Figure B.1 Case Front ControlsAIR Carbon ARC Cutting Constant Current ProcessesManual ARC Welding Stick 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 Retest After Repair Maximum Acceptable Output AT Minimum Output SettingsMinimum Acceptable Output AT Maximum Output Settings 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