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V250-S service manual
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Contents
Main
INVERTEC V250-S
SERVICE MANUAL
SVM124-A
FOR ENGINE powered equipment.
i
WARNING
ELECTRIC AND MAGNETIC FIELDS may be dangerous
ii
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
FUMES AND GASES can be dangerous.
FOR ELECTRICALLY powered equipment.
CYLINDER may explode if damaged.
iii
WELDING SPARKS can cause fire or explosion.
iv
PRCAUTIONS DE SRET
PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR
vi
MASTER TABLE OF CONTENTS FOR ALLSECTIONS
SECTION-A-1
TABLE OF CONTENTS -INSTALLATION SECTION-
A-2
Technical Specifications - Invertec V250-S
A-2
OUTPUT
PHYSICAL DIMENSIONS
INPUT
SAFETY PRECAUTIONS
ELECTRIC SHOCK
SELECT SUITABLE LOCATION
STACKING
TILTING
INPUT VOLTAGE RECONNECT PROCEDURE
RECONNECT PROCEDURE
'A'
A-5
+
OUTPUT CONNECTIONS
REMOTE CONTROL RECEPTACLE
OUTPUT CABLES
QUICK DISCONNECT PLUGS
Page
SECTION-B-1SECTION-B-1
TABLE OF CONTENTS -OPERATION SECTION-
B-2
GENERAL DESCRIPTION
OPERATIONALFEATURES
WELDING CAPABILITY
LIMITATIONS
SAFETY INSTRUCTIONS
-
B-3
+
I
O
CONSTANT CURRENT PROCESSES
MANUAL ARC WELDING (STICK)
AIR CARBON ARC CUTTING
TIG WELDING
B-5
PARALLEL OPERATION
OVERLOAD PROTECTION
THERMAL PROTECTION
Page
SECTION C-1
ACCESSORIES
SECTION C-1
TABLE OF CONTENTS -ACCESSORIES SECTION-
C-2
ACCESSORIES
C-2
OPTIONS / ACCESSORIES
CABLE PLUGS
REMOTE CONTROLS
Page
D-2
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE
ELECTRIC SHOCK
D-3
ROUTINE MAINTENANCE
FILTER CAPACITOR CONDITIONING
D-4
TABLE OF CONTENTS -THEORY OF OPERATION SECTION-
E-2
CONTROL BOARD
SHUNT
INPUT LINE VOLTAGE
FIGURE E.1 - INPUT VOLTAGE CIRCUITS
LINE SWITCH
RECTIFIER
AUXILIARY
PRECHARGE AND PROTECTION
IGBT Operation Discussion and diagrams
MAIN TRANSFORMER
E-5
CONTROL BOARD
SHUNT
OUTPUT RECTIFICATION AND CONTROL
IGBT Operation
Discussion in this section.
FIGURE E.4 OUTPUT RECTIFICATION AND CONTROL
LINE SWITCH
PROTECTION CIRCUITS
OVERLOAD PROTECTION
THERMAL PROTECTION
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION
PULSE WIDTH MODULATION
MINIMUM OUTPUT
MAXIMUM OUTPUT
TABLE OF CONTENTS -TROUBLESHOOTING & REPAIR SECTION-
Step 1. LOCATE PROBLEM (SYMPTOM).
Step 2. PERFORM EXTERNAL TESTS.
Step 3. RECOMMENDED COURSE OF ACTION
HOW TO USE TROUBLESHOOTING GUIDE
OSCILLOSCOPE WARNING
_______________________________
PC BOARD TROUBLESHOOTING PROCEDURES
F-4
Input Voltage Reconnect
F-5
Voltage Checks
Input Filter Capacitor Conditioning
Protection Circuit
Control Board Voltage Checks
F-6
Capacitor Balance Test
Input Voltage Reconnect Procedure
F-7
Resistance Test
Input Rectifier Test
Installation Section
Protection Circuit
Page
F-9
WELDING PROBLEMS
Installation Section
Control Board Voltage
Page
AUXILIARY TRANSFORMER TEST
Table F.1
AUXILIARY TRANSFORMER TEST (continued)
1J7 2J7 3J7 4J7 5J7 6J7
Figure F.1 Auxiliary Transformer and Plug J7.
AUXILIARY TRANSFOMER PLUG J7
AUXILIARY TRANSFORMER TEST (continued)
TABLE F.1 Auxiliary Transformer Test Points
Page
Page
Page
Power Board Resistance
Input Rectifier Bridge Removal And Replacement
INPUT RECTIFIER TEST (continued)
TABLE F.2 Input Rectifier Test Points
Page
Page
POWER BOARD RESISTANCE TEST (continued)
+
Figure F.3 Power Board Test Points.
+
Removal and Replacement
Power Board Voltage Test
POWER BOARD RESISTANCE TEST (continued)
TABLE F.3 Power Board Resistance Test Points.
Page
Page
OUTPUT DIODES TEST (continued)
-
Figure F.4 Machine Output Terminals.
INVERTEC V250-S
+
I
-
Figure F.5 Meter Probes.
INVERTEC V250-S
O
I
DIODE MODULES
POWER BOARD VOLTAGE TEST
Table F.4
POWER BOARD VOLTAGE TEST (continued)
+ +
PLUG J6
Figure F.8 Plug J6 on Power Board
#308 (1J6) #307 (2J6)
POWER BOARD VOLTAGE TEST (continued)
TABLE F.4. Power Board Voltage Test Points.
TEST POINTS
ACCEPTABLE VOLTAGES
TEST CONDITIONS
Page
CONTROL BOARD VOLTAGE TEST
Filter Capacitor Discharge Procedure
Table F.5
CONTROL BOARD VOLTAGE TEST (continued)
G2666-[ ]
Figure F.9 Plugs J1-J5 on Control Board
V250S CONTROL
CONTROL BOARD VOLTAGE TEST (continued)
TABLE F.5. Control Board Voltage Test Points.
TEST POINTS
ACCEPTABLE VOLTAGES
TEST CONDITIONS
Page
PROTECTION CIRCUIT TEST
PROTECTION CIRCUIT TEST (continued)
1J2
Figure F.11
PLUG J6
8J2 6J2
PROTECTION CIRCUIT TEST (continued)
PROTECTION CIRCUIT (SIMPLIFIED)
Page
CAPACITOR BALANCE TEST
CAPACITOR BALANCE TEST (continued)
+
Figure F.12 Power Board and Capacitor Test Locations
+
CAPACITOR (C2) TERMINALS
CAPACITOR (C1) TERMINALS
maintenance
CAPACITOR BALANCE TEST (continued)
TABLE F.6 Capacitor Voltages
Page
CONTROL BOARD REMOVALAND REPLACEMENT
CONTROL BOARD REMOVALAND REPLACEMENT (continued)
DEPRESS LOCKING TAB ON MOUNTING PIN
Figure F.13
SIX MOUNTING TABS
POWER BOARD REMOVALAND REPLACEMENT
POWER BOARD REMOVALAND REPLACEMENT (continued)
204
Figure F.14
+
4 SOCKET HEAD
CAP SCREWS
Filter Capacitor Removal and Replacement
POWER BOARD REMOVALAND REPLACEMENT (continued)
Page
FILTER CAPACITOR REMOVAL AND REPLACEMENT
FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued)
Replacement Procedure
FILTER CAPACITOR REMOVALAND REPLACEMENT (continued)
Page
INPUT RECTIFIER BRIDGE REMOVALAND REPLACEMENT
Page
INPUT RECTIFIER BRIDGE REMOVALAND REPLACEMENT (continued)
Page
Page
Figure F.15
SLEEVED SPLICES
SNUBBER RESISTORS 7/16 BOLT
Figure F.17 Output Diode Assembly and Leads
Figure F.15
Figure F.17
LOCKING TABS
Figure F.18 Heatsink Removal
Page
Page
DIODE MODULES
7/16 BOLTED CONNECTIONS
Figure F.19 Output Diode Assembly and Leads
7/16 MOUNTING BOLTS
Page
Page
Page
201 204
205
Figure F.20 Main Transformer Right Side
208 T3 CURRENT TRANSFORMER MAIN TRANSFORMER
Figure F.22
MAIN TRANSFORMER SECONDARY LEADS
Figure F.21 Main Transformer Left Side
MOUNTING SCREWS
LOCKING MOUNTING TABS
Figure F.22 Main Transformer Mountings
(MACHINE CODES BELOW 10150)
Page
Page
Figure F.24.
201 204
205
Figure F.23 Main Transformer Right Side
208 T3 CURRENT TRANSFORMER MAIN TRANSFORMER
Figure F.25
MAIN TRANSFORMER SECONDARY LEADS
Figure F.24 Main Transformer Left Side
MOUNTING SCREWS
LOCKING MOUNTING TABS
Figure F.25 Main Transformer Mountings
Page
Page
RETEST AFTER REPAIR
Page
Page
Page
G-2
Wiring Diagram (Codes 10102, 10103)
-
CLEVELAND, OHIO U.S.A.
+ ARC - ARC
8-5-94 L9280
A B CD
+
F
+ ARC - ARC
9-29-95E L9907
A B CD
+
F
G-4
Control PC Board (G2666) Layout
G2666
G2666
R46
G-4
G-5
Power PC Board (G2684) Layout
G2684
POWER P.C. BD. AS'BLY
A1
G-5
G-6
Control PC Board (G2666) Schematic
2
4
OPEN
G-6
G-7
Power PC Board (G2684) Schematic
LC
R74
R50
G-7