Lincoln Electric V250-S service manual Possible Areas Recommended Symptoms, Course of Action

Page 36

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F-4

TROUBLESHOOTING & REPAIR

F-4

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

 

Major physical or electrical damage

Contact your local Lincoln

Contact Lincoln Electric Service

 

is observed when cover wrap-around

Authorized Field Service Facility.

Department (216)-383-2531

or

 

is removed.

 

 

1-800-833-9353

 

 

 

 

 

 

The machine is dead - no output -

1. The input power switch must be

1. The power switch (S1) may be

 

no fan.

 

 

in the ON position.

faulty. Check or replace.

 

 

 

 

2.

Make sure the input voltage is

2. Check for loose or broken leads

 

 

 

 

correct for the machine.

between the power switch (S1)

 

 

 

 

 

and the input rectifier D9. See

 

 

 

3.

If the machine is set for single-

wiring diagram.

 

 

 

 

 

phase operation, inspect to

 

 

 

 

 

 

assure that the WHITE and

3. Perform the Auxiliary

 

 

 

 

 

BLACK leads are connected

Transformer Test.

 

 

 

 

 

properly and the RED lead is not

 

 

 

 

 

 

connected and is insulated.

 

 

 

 

 

4. Check that the input voltage set-

 

 

 

 

 

 

up switch and jumper “A” (the

 

 

 

 

 

 

reconnect auxiliary jumper) are in

 

 

 

 

 

 

the proper position for the input

 

 

 

 

 

 

voltage being applied. Refer to

 

 

 

 

 

 

Input Voltage Reconnect

 

 

 

 

 

 

Procedure in the Installation

 

 

 

 

 

 

Chapter.

 

 

 

 

 

5. Check continuity of the 0.6-amp

 

 

 

 

 

 

slow blow fuse located on the

 

 

 

 

 

 

reconnect panel.

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

INVERTEC V250-S

Image 36
Contents Invertec V250-S Safety Electric Shock can kill ARC Rays can burnFumes 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 SectionTechnical Specifications Invertec V250-S Three Phase Single PhaseThree Phase Safety Precautions Input ConnectionsSelect Suitable Location Input Voltage Reconnect Procedure Input Fuse and Supply WirePower 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 WeldingParallel Operation Overload ProtectionThermal Protection Invertec V250-S Accessories Table of Contents Accessories SectionOptions / Accessories Remote ControlsCable 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 Pulse Width Modulation Minimum OutputMaximum 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 Auxiliary Transformer Test Test DescriptionMaterials 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 BoardTable F.4. Power Board Voltage Test Points Acceptable Test DescriptionTest 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 Control Board Removal and Replacement ProcedureV250S 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