RETURN TO MAIN MENU IM490-C INVERTEC ™ V250-S For use with machines having Code Numbers: February, 2001 10102, 10103, 10187, 10188, 10304, Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS PAGE INSTALLATION .......................................................................................................................SECTION A TECHNICAL SPECIFICATIONS ........................................................................................A-1 & A-2 SAFETY PRECAUTIONS ............................................................................................................A-3 SELECT SUITABLE LOCATION.................................................................
A-1 A-1 INSTALLATION Technical Specifications - Invertec V250-S - K1436-1, K1437-1 & K1437-3 INPUT THREE PHASE SINGLE PHASE Standard Input Current at Rated Output Voltage 208/230/460 60Hz 34/32/16 200/220/400/440 50/60Hz 35/33/18/17 380-415 50Hz 20/18 Model 60Hz 50/60 Hz 50Hz Standard Input Current at Rated Output Voltage 208/230/460 60Hz 59/57/29 200/220/400/440 50/60 Hz 58/58/30/30 Model 60Hz 50/60 Hz RATED OUTPUT THREE PHASE Duty Cycle(1) 35% Duty Cycle 60% Duty Cycle 100% Duty Cycle 35% Duty Cy
A-2 A-2 INSTALLATION Technical Specifications - Invertec V250-S - K1437-2 INPUT THREE PHASE SINGLE PHASE Standard Input Current at Rated Output Voltage 220/440 35% Duty Cycle 34/17 400 60% Duty Cycle 16 220/400/440 100% Duty Cycle 19/11/9 Model 50/60 Hz 50/60 Hz 50/60 Hz Standard Input Current at Rated Output Voltage 220/440 35% Duty Cycle 57/29 400 60% Duty Cycle 27 220/400/440 100% Duty Cycle 34/21/17 Model 50/60 Hz 50/60 Hz 50/60 Hz RATED OUTPUT THREE PHASE Duty Cycle (1) SINGLE PHASE Amps
A-3 INSTALLATION Read this entire installation section before you start installation. A-3 HIGH FREQUENCY PRECAUTIONS If possible locate the V250-S away from radio controlled machinery. The normal operation of the V250-S may adversely affect the operation of RF controlled equipment, which may result in bodily injury or damage to the equipment. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment.
A-4 A-4 INSTALLATION INPUT VOLTAGE RECONNECT PROCEDURE POWER INPUT CONNECTION FOR 50/60 HZ MACHINES 1. Connect terminal marked to earth ground per National Electric Code. 2. Connect the supply lines to the line switch. Torque to 3.0 Nm. 3. Install in accordance with all local and national electric codes. When received directly from the factory, units are connected for the highest input voltage, 440 VAC for 50/60 Hz machines and 460 VAC for 60 Hz machines.
A-5 A-5 INSTALLATION OUTPUT CONNECTIONS QUICK DISCONNECT PLUGS Refer to figure A.2 for the location of the 6 Pin Remote Receptacle and the Output Terminals. FIGURE A.2 OUTPUT CONNECTIONS A quick disconnect system is used for the welding cable connections. The welding plug included with the machine is designed to accept a welding cable size of 1/0 to 2/0. 1. Remove 1 in. (25mm) of welding cable insulation. SMAW SOFT GTAW SMAW CRISP THERMAL HOT START 4 5 6 2. Slide rubber boot onto cable end.
B-1 OPERATION Read and understand this entire section before operating your machine. B-1 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). SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill. OPERATIONAL FEATURES • Do not touch electrically live parts such as output terminals or internal wiring.
B-2 B-2 OPERATION CONTROLS AND SETTINGS All operator controls and adjustments are located on the case front of the V250-S. Refer to Figure B.1 and corresponding explanations. FIGURE B.1 — CASE FRONT CONTROLS. 4 8 SMAW SOFT SMAW CRISP GTAW THERMAL HOT START 4 2 5 6 7 3 A 85 50 15 REMOTE LOCAL 0 170 5 9 1 OUTPUT 3 8 2 120 10 ARC FORCE 230 1 4 5 6 7 3 250 8 2 6 9 1 0 10 ® INVERTEC V250-S + - I S 1 O 7 1.
B-3 OPERATION 6. Arc Force - This control functions in SMAW modes to adjust the Arc Force. The arc is soft at the minimum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings.
B-4 OPERATION PARALLEL OPERATION The Invertec’s are operable in parallel. For best results, the currents of each machine should be reasonably well shared. As an example, with two machines set up in parallel for a 300 amp procedure, each machine should be set to deliver approximately 150 amps, not 200 amps from one and 100 amps from the other. This will minimize nuisance feedback conditions.
C-1 ACCESSORIES OPTIONS / ACCESSORIES CABLE PLUGS K852-70 - Cable Plug Kit for 1/0-2/0 cable. Attaches to welding cable to provide quick disconnect from machine. K852-95 - Cable Plug Kit for 2.0-3/0 cable. NOTE: Two K852-70 plugs are included with the V250-S. REMOTE CONTROLS K857 - Remote Output Control for stick welding. K963 - Hand Amptrol tm for TIG welding. When the V250-S’s Output Control is in the “Remote” position, the hand Amptrol energizes the output and controls the output remotely.
D-1 D-1 MAINTENANCE WARNING ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • Prior to Performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock. --------------------------------------------------------------------- 4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum).
D-2 MAINTENANCE D-2 ROUTINE MAINTENANCE FILTER CAPACITOR CONDITIONING 1. Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. A protection circuit is included to monitor the voltage across filter capacitors C1 and C2. In the event that the capacitor voltage is too high, the protection circuit will prevent output. Nominal trip setting is at 230/460 VAC +15%.
D-3 D-3 MAINTENANCE FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
E-1 TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts. _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
E-2 TROUBLESHOOTING & REPAIR E-2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is observed when cover wrap-around is removed. The machine is dead - no output no fan. 1. The input power switch must be in the ON position. 2. Make sure the input voltage is correct for the machine. 3.
E-3 TROUBLESHOOTING & REPAIR E-3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No output but the fan operates normally. 1. The mode switch must be in one of the SMAW modes or if in the GTAW mode the remote trigger circuit must be activated. 2. The Local/Remote switch (S3) must be in the LOCAL position unless a remote control device is attached to the remote receptacle. 3.
E-4 TROUBLESHOOTING & REPAIR E-4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Output turns on momentarily, then switches off and repeats cycle. 1. Check the input voltages and reconnection procedures. Make sure the input voltage is correct for the machine. See Input Voltage Reconnect Procedure. 2. Check or replace remote control device.
E-5 TROUBLESHOOTING & REPAIR E-5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No output - Main input fuses open, indicating excessive current draw. 1. Inspect input leads for possible shorts or grounds or mis-connections. 2. Install new fuses and reapply power. If fuses open again, consult a Lincoln Authorized Field Service Facility.
E-6 TROUBLESHOOTING & REPAIR E-6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS The machine will not produce more than 200 amps. 1. This may be normal operation. If the output current exceeds 290 amps, an electronic protection circuit will reduce the current to less than 200 amps.
E-7 TROUBLESHOOTING & REPAIR E-7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Poor welding, weld settings drift, or output power is low. 1. Make sure the machine settings are correct for the weld process being used. 2. Check machine performance on LOCAL control. If OK then the remote control device may be faulty. Check or replace. 3.
INVERTEC V250-S TP2 TP1 0.6 AMP SLOW BLOW W V ON N.C. A A TP3 202 202A A H3 H1 A H1 H1 203 203 D9 415V 380- 230V 220- 208V 200- 460V H3 BRIDGE INPUT 440- C B A 203A 202 C2 209 T2 18V R 313 309 5 6 H5 H4 5 6 3 2 4 H2 H3 1 J7 H1 TRANSFORMER AUXILIARY H5 H4 H3 H2 R 2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
S1 INVERTEC V250-S ON TP2 TP1 0.6 AMP SLOW BLOW W V U 206 A A TP3 202 202A 207 N.C.
BASE INVERTEC V250-S G B R W V PANEL A BLOW N.C.
INVERTEC V250-S TP3 TERMINAL SIDE REAR TERMINAL TP2 TP1 H4A 0.6 AMP H4 BLOW SLOW H3 H1 H1 H1 H4A D9 400V 220V 3 H4 5 6 2 4 1 J7 T2 18V THERMOSTAT TRANSFORMER R R POWER BOARD 209 - 207A HEATSINK AUXILIARY H5 H4 H3 H2 H1 MOTORS FAN 209 1600/450 207A H3 H1 D BRIDGE INPUT 0V A B F 202A J6 CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. Y I 310 311 313 309 4 5 6 T1 J1 MAIN S F S J5, J6, J7 J2 F AUX.
9.13 12.58 15.04 DIMENSION PRINT 19.
NOTES INVERTEC V250-S
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● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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