Lincoln Electric V250-S service manual Capacitor Balance Test

Page 38

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F-6

TROUBLESHOOTING & REPAIR

F-6

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

 

PROBLEMS

 

POSSIBLE AREAS OF

RECOMMENDED

 

 

(SYMPTOMS)

 

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

 

Output turns on momentarily, then 1.

Check the input voltages and

1. Check Local/Remote switch (S3)

switches off and repeats cycle.

reconnection procedures. Make

and associated wiring for loose or

 

 

 

sure the input voltage is correct

faulty connections.

 

 

 

 

for the machine. See Input

 

 

 

 

 

Voltage Reconnect Procedure. 2. Check Mode Switch (S2) and

 

 

 

 

 

associated wiring for loose or

 

 

2.

Check or replace remote control

faulty connections.

 

 

 

 

device. (If used)

 

 

 

 

 

 

3. If the machine is connected for

 

 

 

 

380VAC input or higher, perform

 

 

 

 

the Capacitor Balance Test.

 

 

 

 

 

4. The power board may be faulty.

 

 

 

 

Replace.

 

 

 

 

 

5. The control board may be faulty.

 

 

 

 

Replace.

 

Remote output control not

1.

Make sure the Local/Remote

1.

Check the Local/Remote switch

functioning. The machine operates

 

switch (S3) is in the REMOTE

 

(S3) and the associated wiring.

normally on LOCAL control.

 

position.

 

See wiring diagram.

 

2.

The remote control device may

2.

Check for loose or faulty

 

 

be faulty. Replace.

 

connections at the remote control

 

 

 

 

receptacle.

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

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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
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