Safety Instructions, Gouging Sparks | Lincoln Electric V250-S

B-2

OPERATION

B-2

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Read and understand this entire section before operating your machine.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

GENERAL DESCRIPTION

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

OPERATIONAL FEATURES

The Invertec V250-S provides continuous total range output current adjustment, selectable welding modes and local or remote output control. Welding character- istics can be controlled via an arc force control. Additionally, starting characteristics can be adjusted via a “hot start” control.

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FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

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WELDING, CUTTING and

GOUGING SPARKS

can cause fire or explosion

•Keep flammable material away.

•Do not weld, cut or gouge on containers that have held com-

bustibles.

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ARC RAYS can burn.

•Wear eye, ear and body protection.

WELDING CAPABILITY

The Invertec V250-S is rated at 250 amps, 35% duty cycle (based on a 10 minute cycle). It is also rated at 165 amps, 100% duty cycle, and 200 amps, 60% duty cycle.

LIMITATIONS

The V250-S is not recommended for pipe thawing.

The V250-S should not be powered from the auxiliary power supply of an engine welder. Special protection circuits may operate causing loss of output.

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Only qualified personnel should operate this equip- ment. Observe all safety information throughout this manual.

INVERTEC V250-S

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Lincoln Electric V250-S service manual Safety Instructions, Gouging Sparks

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 explosion Précautions DE Sûreté Sûreté Pour Soudage a L’Arc Master Table of Contents for ALL Sections Installation Table of Contents Installation Section Three 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 Cables Invertec V250-S Operation Safety Instructions Gouging Sparks Controls and Settings Figure B.1 Case Front Controls AIR Carbon ARC Cutting Constant Current ProcessesManual ARC Welding Stick TIG Welding Thermal Protection Parallel OperationOverload Protection Invertec V250-S Accessories Table of Contents Accessories Section Cable Plugs Options / AccessoriesRemote Controls Maintenance Table of Contents Maintenance Section Input Filter Capacitor Discharge Procedure Figure D.1 Location of Input Filter Capacitor Terminals Routine Maintenance Filter Capacitor Conditioning Figure D.2 Location of Maintenance Components Table of Contents Theory of Operation Section Theory of Operation General Description Input Line Voltage Precharge and Protection Figure E.2 Protection and PRE-CHARGE Circuits Main Transformer Figure E.3 Main Transformer Output Rectification Control Figure E.4 Output Rectification and Control Protection Circuits Overload Protection Insulated Gate Bipolar Transistor Igbt Operation Maximum Output Pulse Width ModulationMinimum Output Troubleshooting & Repair HOW to USE Troubleshooting Guide Oscilloscope Warning PC Board Troubleshooting Procedures Board can be dam- aged by static electricity Possible Areas Recommended Symptoms Course of Action Possible Areas Perform the Control Board Voltage Checks Capacitor Balance Test Troubleshooting & Repair Perform the Output Diode Test Welding Problems Invertec V250-S Materials Needed Auxiliary Transformer TestTest Description Test Procedure Auxiliary Transformer Test Auxiliary Transformer Test Table F.1 Auxiliary Transformer Test Points Invertec V250-S Input Rectifier Test Test Procedure Input Rectifier Test Table F.2 Input Rectifier Test Points Test Point Terminals Analog Meter X10 Range Invertec V250-S Power Board Resistance Test Power Board Resistance Test Test Description Power Board Resistance Test Table F.3 Power Board Resistance Test Points Invertec V250-S Output Diodes Test Output Diodes Test Figure F.4 Machine Output Terminals Invertec V250-S Diode Modules Power Board Voltage Test Power Board Voltage Test Figure F.8 Plug J6 on Power Board Test 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 Board Table F.5. Control Board Voltage Test Points 18VAC Invertec V250-S Protection Circuit Test Protection Circuit Test Figure F.10 Control Board Plug J2 Test Points Protection Circuit Simplified Invertec V250-S Capacitor Balance Test Figure F.12 Power Board and Capacitor Test Locations Capacitor Balance Test Table 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 Locations Power Board Replacement Procedure Invertec V250-S Filter Capacitor Removal and Replacement Matched Parts Filter Capacitor Removal and Replacement Figure F.15 Heatsink/Power Board Removal Perform 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 Locations Troubleshooting & 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 Watts Invertec V250-S Electrical Diagrams Invertec V250-S Wiring Diagram Codes 10102 Invertec V250S Wiring Diagram Codes 10187 Return to Section Control PC Board G2666 Layout G2666 Power PC Board G2684 Layout Power P.C. BD. Asbly Control PC Board G2666 Schematic Relay Coils Power PC Board G2684 Schematic From Control BD