Lincoln Electric V250-S Safety Precautions, Input Connections, Select Suitable Location

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INSTALLATION

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Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

•Have an electrician install and ser- vice this equipment.

•Turn the input power off at the fuse box before working on equipment.

•Do not touch electrically hot parts.

•Be sure to discharge capacitors with the procedure outlined in the Maintenance Section of this manual before working in that area of the equipment.

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HIGH FREQUENCY PRECAUTIONS

If possible locate the V250-S away from radio con- trolled machinery. The normal operation of the V250-S may adversely affect the operation of RF con- trolled equipment, which may result in bodily injury or damage to the equipment.

INPUT CONNECTIONS

The Invertec V250-S should be connected only by a qualified electrician. Installation should be made in accordance with all local and national electric codes and the information detailed below.

GROUND CONNECTION

Ground per National Electrical Code for 60Hz machines connect the green lead to earth ground. For 50/60Hz machines connect the ground terminal

marked located in the machine on the lower right side the base of the welder to earth ground.

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SELECT SUITABLE LOCATION

The Invertec V250-S will operate in harsh environ- ments. Even so, it is important that simple preventa- tive measures are followed in order to assure long life and reliable operation.

•The machine must be located where there is free cir- culation of clean air such that air movement in the back and out the front will not be restricted.

•Dirt and dust that can be drawn into the machine should be kept to a minimum. Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown.

•Keep machine dry. Shelter from rain and snow. Do not place on wet ground or in puddles.

STACKING

V250-S’s cannot be stacked.

TILTING

Place the machine directly on a secure, level surface or on a recommended undercarriage. The machine may topple over if this procedure is not followed.

INPUT SUPPLY CONNECTIONS

Be sure the voltage phase and frequency of the input power is as specified on the rating plate, located on the rear of the machine.

Supply line entry provision is in the case rear panel.

POWER INPUT CONNECTION FOR 60HZ MACHINES

A 10 ft. power cord is provided and wired into the machine. Follow the power cord connection instruc- tions. Incorrect connection may result in equipment damage.

Single Phase Input: Connect green lead to ground per U.S. National Electrical Code. Connect black and white leads to power. Wrap red lead with tape to pro- vide 600V insulation.

Three Phase Input: Connect green lead to ground per U.S. National Electrical Code. Connect black, red and white leads to power.

INVERTEC V250-S

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Contents Invertec V250-S Safety Electric Shock can kill ARC Rays can burnFumes and Gases can be dangerous Welding Sparks can cause fire or explosion Cylinder may explode if damagedSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section InstallationTechnical 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 Output Connections Remote Control ReceptacleQuick Disconnect Plugs Output CablesInvertec V250-S Operation Gouging Sparks Safety InstructionsFigure B.1 Case Front Controls Controls and SettingsManual ARC Welding Stick Constant Current ProcessesAIR Carbon ARC Cutting TIG WeldingParallel Operation Overload ProtectionThermal Protection Invertec V250-S Table of Contents Accessories Section AccessoriesOptions / Accessories Remote ControlsCable Plugs Table of Contents Maintenance Section MaintenanceFigure D.1 Location of Input Filter Capacitor Terminals Input Filter Capacitor Discharge ProcedureFilter Capacitor Conditioning Routine MaintenanceFigure D.2 Location of Maintenance Components Theory of Operation Table of Contents Theory of Operation SectionInput Line Voltage General DescriptionFigure E.2 Protection and PRE-CHARGE Circuits Precharge and ProtectionFigure E.3 Main Transformer Main TransformerFigure E.4 Output Rectification and Control Output Rectification ControlOverload Protection Protection CircuitsInsulated Gate Bipolar Transistor Igbt Operation Pulse Width Modulation Minimum OutputMaximum Output Troubleshooting & Repair Oscilloscope Warning HOW to USE Troubleshooting GuideBoard can be dam- aged by static electricity PC Board Troubleshooting ProceduresCourse of Action Possible Areas Recommended SymptomsPerform the Control Board Voltage Checks Possible AreasCapacitor Balance Test Troubleshooting & Repair Perform the Output Diode Test Welding Problems Invertec V250-S Auxiliary Transformer Test Test DescriptionMaterials Needed Auxiliary Transformer Test Test ProcedureTable F.1 Auxiliary Transformer Test Points Auxiliary Transformer TestInvertec V250-S Input Rectifier Test Input Rectifier Test Test ProcedureTest Point Terminals Analog Meter X10 Range Table F.2 Input Rectifier Test PointsInvertec V250-S Power Board Resistance Test Test Description Power Board Resistance TestTable F.3 Power Board Resistance Test Points Power Board Resistance TestInvertec V250-S Output Diodes Test Figure F.4 Machine Output Terminals Output Diodes TestInvertec V250-S Diode Modules Power Board Voltage Test Figure F.8 Plug J6 on Power Board Power Board Voltage TestTable F.4. Power Board Voltage Test Points Acceptable Test DescriptionTest Conditions Invertec V250-S Control Board Voltage Test Figure F.9 Plugs J1-J5 on Control Board Control Board Voltage Test18VAC Table F.5. Control Board Voltage Test PointsInvertec V250-S Protection Circuit Test Figure F.10 Control Board Plug J2 Test Points Protection Circuit TestProtection Circuit Simplified Invertec V250-S Capacitor Balance Test Capacitor Balance Test Figure F.12 Power Board and Capacitor Test LocationsTable F.6 Capacitor Voltages Invertec V250-S Control Board Removal and Replacement Control Board Removal and Replacement ProcedureV250S Control Power Board Removal and Replacement Figure F.14 Power Board Lead Locations Power Board Removal and ReplacementPower Board Replacement Procedure Invertec V250-S Matched Parts Filter Capacitor Removal and ReplacementFigure F.15 Heatsink/Power Board Removal Filter Capacitor Removal and ReplacementPerform Power Board Replacement Procedure in this section Invertec V250-S Input Rectifier Bridge Removal and Replacement Figure F.16 Input Rectifier Lead Locations Input Rectifier Bridge Removal and ReplacementTroubleshooting & 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 Minimum Acceptable Output AT Maximum Output Settings Maximum Acceptable Output AT Minimum Output SettingsRetest After Repair Input Idle Amps and Idle WattsInvertec V250-S Electrical Diagrams Invertec V250-S Invertec V250S Wiring Diagram Codes 10102Return to Section Wiring Diagram Codes 10187G2666 Control PC Board G2666 LayoutPower P.C. BD. Asbly Power PC Board G2684 LayoutRelay Coils Control PC Board G2666 SchematicFrom Control BD Power PC Board G2684 Schematic
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