SVM124-A INVERTEC V250-S View Safety Info Return to Master TOC RETURN TO MAIN INDEX July, 1996 For use with machine Code Numbers 10102 to 10188 Return to Master TOC View Safety Info Return to Master TOC View Safety Info 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.
Return to Master TOC 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.
Return to Master TOC Return to Master TOC ii 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.
Return to Master TOC iii 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.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC 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.
vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX PAGE INSTALLATION .......................................................................................................................SECTION A TECHNICAL SPECIFICATIONS ..................................................................................................A-2 SAFETY PRECAUTIONS ............................................................................................................A-3 SELECT SUITABLE LOCATION..............
INSTALLATION SECTION-A-1 TABLE OF CONTENTS -INSTALLATION SECTIONTECHNICAL SPECIFICATIONS ..................................................................................................A-2 SAFETY PRECAUTIONS ............................................................................................................A-3 SELECT SUITABLE LOCATION..................................................................................................A-3 STACKING......................................................
Return to Master TOC Return to Section TOC A-2 A-2 INSTALLATION Technical Specifications - Invertec V250-S INPUT THREE PHASE Standard Voltage 208/230/460 200/220/400/440 SINGLE PHASE Input Current at Rated Output 34/32/16 35/33/18/17 Model 60Hz 50/60 Hz 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 Return to Master TOC Return to Section TOC (1) Duty Cycle 35% Duty Cycle 60% Duty Cycle
Return to Master TOC Return to Section TOC 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.
Return to Master TOC Return to Section TOC A-4 POWER INPUT CONNECTION FOR 50/60 HZ MACHINES INPUT VOLTAGE RECONNECT PROCEDURE 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.
Return to Master TOC Return to Section TOC 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. 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. SMAW SOFT GTAW SMAW CRISP 1. Remove 1 in. (25mm) of welding cable insulation.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC A-6 NOTES INVERTEC V250-S A-6
OPERATION SECTION-B-1 TABLE OF CONTENTS -OPERATION SECTIONSAFETY INSTRUCTIONS ...........................................................................................................B-2 GENERAL DESCRIPTION...........................................................................................................B-2 OPERATIONAL FEATURES .................................................................................................B-2 WELDING CAPABILITY ..................................................
Return to Master TOC Return to Section TOC B-2 OPERATION Read and understand this entire section before operating your machine. WARNING ELECTRIC SHOCK can kill. OPERATIONAL FEATURES Return to Master TOC Return to Section TOC • Insulate yourself from the work and ground. • Always wear dry insulating gloves. WELDING CAPABILITY FUMES AND GASES can be dangerous. The Invertec V250-S is rated at 250 amps, 35% duty cycle (based on a 10 minute cycle).
Return to Master TOC Return to Section TOC B-3 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.
Return to Master TOC Return to Section TOC B-4 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.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC B-5 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.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC B-6 NOTES INVERTEC V250-S B-6
ACCESSORIES SECTION C-1 TABLE OF CONTENTS -ACCESSORIES SECTIONOPTIONS / ACCESSORIES ........................................................................................................C-2 CABLE PLUGS......................................................................................................................C-2 K852-70 .......................................................................................................................C-2 K852-95 ..............................................
Return to Master TOC Return to Section TOC C-2 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. Return to Master TOC Return to Section TOC REMOTE CONTROLS K857 - Remote Output Control for stick welding. K963 - Hand Amptrol tm for TIG welding.
MAINTENANCE SECTION D-1 TABLE OF CONTENTS -MAINTENANCE SECTIONINPUT FILTER CAPACITOR DISCHARGE PROCEDURE.........................................................D-2 ROUTINE MAINTENANCE..........................................................................................................D-3 FILTER CAPACITOR CONDITIONING ......................................................................................D-3 LOCATION OF MAINTENANCE COMPONENTS..............................................................
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC D-2 D-2 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.
Return to Master TOC Return to Section TOC D-3 ROUTINE MAINTENANCE 1. 2. Return to Master TOC 3. Return to Section TOC MAINTENANCE 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. Remove the machine wrap-around cover and perform the input filter capacitor discharge procedure (detail at the beginning of this chapter).
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC D-4 D-4 MAINTENANCE FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
THEORY OF OPERATION TABLE OF CONTENTS -THEORY OF OPERATION SECTIONGENERAL DESCRIPTION...........................................................................................................E-2 INPUT LINE VOLTAGE................................................................................................................E-2 PRE-CHARGE AND PROTECTION ............................................................................................E-3 MAIN TRANSFORMER............................................
Return to Master TOC Return to Section TOC E-2 GENERAL DESCRIPTION The Invertec V250-S is a 250 amp arc welding power source that utilizes either single or three phase input power to produce a constant current output. The output response of this machine has been optimized for the SMAW and TIG welding processes. FIGURE E.
Return to Master TOC Return to Section TOC E-3 FIGURE E.
Return to Master TOC Return to Section TOC E-4 FIGURE E.
Return to Master TOC Return to Section TOC E-5 FIGURE E.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-6 THEORY OF OPERATION PROTECTION CIRCUITS Protective circuits are designed into the V250-S machine to sense trouble and shut down the machine before the trouble damages the internal machine components. Both overload and thermal protection circuits are included. OVERLOAD PROTECTION THERMAL PROTECTION The V250-S is electrically protected from producing high output currents.
E-7 E-7 Return to Section TOC Return to Master TOC INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION Return to Section TOC Return to Master TOC THEORY OF OPERATION Drawing B shows the IGBT in an active mode. When the gate signal, a positive DC voltage relative to the An IGBT is a type of transistor. IGBTs are semiconductors well suited for high frequency switching and high current applications. Drawing A shows an IGBT in a passive mode.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC E-8 THEORY OF OPERATION E-8 PULSE WIDTH MODULATION The term PULSE WIDTH MODULATION is used to describe how much time is devoted to conduction in the positive and negative portions of the cycle. Changing the pulse width is known as MODULATION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of the machine.
TROUBLESHOOTING & REPAIR SECTION F-1 TABLE OF CONTENTS -TROUBLESHOOTING & REPAIR SECTIONTROUBLESHOOTING AND REPAIR SECTION.........................................................................SECTION F HOW TO USE TROUBLESHOOTING GUIDE.............................................................................F-2 PC BOARD TROUBLESHOOTING PROCEDURES ...................................................................F-3 TROUBLESHOOTING GUIDE ...............................................................
Return to Master TOC Return to Section TOC F-2 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-3 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. Return to Master TOC Return to Master TOC CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-4 TROUBLESHOOTING & REPAIR F-4 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 Contact your local Lincoln is observed when cover wrap-around Authorized Field Service Facility.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR F-5 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. 1. Perform the Auxiliary Transformer Test. 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-6 TROUBLESHOOTING & REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Return to Section TOC Return to Master TOC Return to Master TOC 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 1. Check Local/Remote switch (S3) reconnection procedures.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-7 TROUBLESHOOTING & REPAIR F-7 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 1. Inspect interior of machine for shorts or grounds or mis-connecphysical signs of electrical and tions.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-8 TROUBLESHOOTING & REPAIR F-8 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 1. Perform the Output Diode Test.
Return to Master TOC TROUBLESHOOTING & REPAIR PROBLEMS (SYMPTOMS) Return to Section TOC Return to Master TOC Return to Master TOC 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. 1. Check the operation of the mode switch (S2) and the associated circuitry. See wiring diagram. 2. Check machine performance on LOCAL control.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-10 NOTES INVERTEC V250-S F-10
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-12 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) 4. Locate and disconnect plug J7 from the wiring harness. TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-13 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) TABLE F.1 Auxiliary Transformer Test Points TEST POINT TEST POINT EXPECTED VOLTAGE H1 (1J7) H2 (4J7) 200 - 208VAC H1 (1J7) H4 (3J7) 380 - 415VAC H1 (1J7) H5 (6J7) 440 - 460VAC RED LEAD (1J1) On Control Board RED LEAD (3J1) On Control Board 18VAC (SECONDARY) 7. If the correct test voltages are present the auxiliary transformer is good.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-14 NOTES INVERTEC V250-S F-14
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-15 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-16 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 4. With the Phillips head screwdriver remove leads #207, 207A and #209 from the rectifier. See Figure F.2. 5. Use the analog ohmmeter to perform the tests detailed in Table F.2. See wiring diagram. Return to Master TOC Return to Section TOC 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (continued) TABLE F.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-18 NOTES INVERTEC V250-S F-18
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR POWER BOARD RESISTANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-20 TROUBLESHOOTING & REPAIR POWER BOARD RESISTANCE TEST (continued) TEST DESCRIPTION 1. Remove main input power to the V250 -S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 4. Carefully remove main transformer primary leads #201, #204, #205 and #208 from the power board. 5. Use the analog ohmmeter to perform the tests outlined in Table F.3. See power board schematic.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR POWER BOARD RESISTANCE TEST (continued) TABLE F.3 Power Board Resistance Test Points.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-22 NOTES INVERTEC V250-S F-22
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR OUTPUT DIODES TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-24 TROUBLESHOOTING & REPAIR OUTPUT DIODES TEST (continued) 4. Using the analog ohmmeter test for more than 200 ohms resistance between positive and negative output terminals. Positive test lead to the positive terminal; Negative test lead to the negative terminal. See Figure F.5. TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Locate the output terminals on the front panel of the machine. See Figure F.4.
Return to Master TOC Return to Section TOC F-25 F-25 TROUBLESHOOTING & REPAIR OUTPUT DIODES TEST (continued) ® INVERTEC V250-S + - I S E E OB -P RO B PR Return to Master TOC + Return to Section TOC O Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Figure F.5 Meter Probes. 5. If more than 200 ohms is measured the output diodes are not “shorted”. 6. If less than 200 ohms is measured, one or more output diodes or snubbers may be shorted or “leaky”.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-26 TROUBLESHOOTING & REPAIR OUTPUT DIODES TEST (continued) OUTPUT DIODES SNUBBERS Figure F.6 Output Diodes and Snubber Locations (Codes 10102 and 10103) Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC DIODE MODULES Figure F.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-27 TROUBLESHOOTING & REPAIR POWER BOARD VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-28 TROUBLESHOOTING & REPAIR POWER BOARD VOLTAGE TEST (continued) 4. The following tests will be performed with the input power applied to the V250-S. BE CAREFUL. ALWAYS REMOVE INPUT POWER AND PERFORM FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT. TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 5. Apply input power and turn On the V250-S. 6.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-29 F-29 TROUBLESHOOTING & REPAIR POWER BOARD VOLTAGE TEST (continued) TABLE F.4. Power Board Voltage Test Points. ACCEPTABLE VOLTAGES TEST DESCRIPTION TEST POINTS The PWM pulse drive from the control board to the pulse transformer primary located on the power board. Lead #307 (2J6) to Negative output terminal 14VDC.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-30 NOTES INVERTEC V250-S F-30
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR CONTROL BOARD VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
CONTROL BOARD VOLTAGE TEST (continued) TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. Return to Master TOC Return to Section TOC 3. Locate and familiarize yourself with the leads and pin locations in plugs J1 thru J5 on the control board. See Figure F.9. Return to Section TOC Return to Master TOC Return to Master TOC J1 J2 4. The following tests will be performed with the input power applied to the V250-S.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-33 F-33 TROUBLESHOOTING & REPAIR CONTROL BOARD VOLTAGE TEST (continued) TABLE F.5. Control Board Voltage Test Points. ACCEPTABLE VOLTAGES TEST DESCRIPTION TEST POINTS The 18VAC from the auxiliary transformer to the control board. Red lead (1J1) to Red lead (3J1) Remote trigger circuit test.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-34 NOTES INVERTEC V250-S F-34
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-35 TROUBLESHOOTING & REPAIR PROTECTION CIRCUIT TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-36 PROTECTION CIRCUIT TEST (continued) TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. Return to Master TOC Return to Section TOC 8J2 3. Locate and familiarize yourself with the leads and pin locations in plug J2 on the control board and also plug J6 on the power board. See Figures F.10. and F.11.
Return to Master TOC PROTECTION CIRCUIT TEST (continued) 4. The following tests will be performed with the input power applied to the V250-S. BE CAREFUL. ALWAYS REMOVE INPUT POWER AND PERFORM FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT. 5. Apply input power and turn ON the V250-S. 6. Check for 0 to 1 VDC at leads #311(4J6)+ to #313(5J6)- at the power board. If the correct voltage is present go to step #7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-38 NOTES INVERTEC V250-S F-38
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-39 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-40 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (continued) 6. The following tests will be performed with the input power applied to the V250-S. BE CAREFUL. ALWAYS REMOVE THE INPUT POWER AND PERFORM FILTER CAPACITOR DISCHARGE PROCEDURE BEFORE TOUCHING ANY MACHINE COMPONENT. TEST PROCEDURE 1. Remove main input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-41 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (continued) 8. Check for the appropriate voltages outlined in Table F.6. Note: Voltages may vary with the input line voltage. 9. If the capacitor voltages are NOT balanced within 20VDC the capacitors may be need “conditioning” . See maintenance section.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-42 NOTES INVERTEC V250-S F-42
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-43 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-44 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL AND REPLACEMENT (continued) Note: Be sure to observe static electricity precautions when handling P.C. boards. PROCEDURE 1. Remove input power to the V250-S. 6. When replacing the control board align the mounting holes with the mounting pins and gently slide the P.C. board onto the mounting pins until the board “snaps” onto the mounting pins. 2.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-45 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-46 F-46 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) 1. Remove input power to the V250-S. 5. Remove plug J6 by depressing the locking tab and removing it from the power board. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 6. With the 7/16” wrench remove the four bolts and washers from the filter capacitor terminals. 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-47 TROUBLESHOOTING & REPAIR POWER BOARD REMOVAL AND REPLACEMENT (continued) 7. Using the 1/4” nut-driver remove the two screws holding the P.C. board to the heat sink mounting bracket. 8. With the 3/16” Allen wrench remove the four socket head cap screws and washers holding the power board to the large aluminum heat sink. 9.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-48 NOTES INVERTEC V250-S F-48
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-49 TROUBLESHOOTING & REPAIR FILTER CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-50 FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 3. Perform Power Board Removal Procedure in this section. 4. Using the 5/16’ nut-driver remove the two screws from the top rear of the case back. See Figure F.15. Return to Master TOC Return to Section TOC F-50 TROUBLESHOOTING & REPAIR 5.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-51 TROUBLESHOOTING & REPAIR FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued) 7. Once the top of the bracket assembly is disengaged from the top center panel the bracket assembly can be removed from the bottom of the case by sliding the bracket assembly towards the front of the machine.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-52 NOTES INVERTEC V250-S F-52
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-53 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-54 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 5. With the Phillips head screwdriver remove the eight leads connected to the rectifier terminals. PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 3.
Return to Master TOC Return to Section TOC F-55 TROUBLESHOOTING & REPAIR INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued) 7. Carefully remove the input rectifier bridge. 8. When installing a new input rectifier apply a thin coating of Dow Corning 340 Heat Sink Compound (Lincoln E1868) to the mating surfaces. Torque the mounting cap screws and nuts to 44 IN-LBS. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC 9.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-56 NOTES INVERTEC V250-S F-56
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-57 TROUBLESHOOTING & REPAIR OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-58 TROUBLESHOOTING & REPAIR OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) 1. Remove input power to the V250-S. 6. Using the 7/16” wrench remove the bolts, nuts and washers from two of the splices. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 7. Using the 3/8” wrench and slot head screwdriver disassemble the other two splices. 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-59 TROUBLESHOOTING & REPAIR OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) LOCKING TABS Return to Master TOC Return to Section TOC Figure F.18 Heatsink Removal 10. Using the slot head screwdriver carefully disengage the output diode heat sink mounting bracket from the top center panel. Also disengage the bottom heat sink mounting bracket from the support bracket.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-60 NOTES INVERTEC V250-S F-60
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-61 TROUBLESHOOTING & REPAIR OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-62 TROUBLESHOOTING & REPAIR OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. 5. Using the 7/16” wrench remove the bolts, nuts and washers from the lead terminals of the module to be replaced. Clear leads and take careful note of lead placement. Return to Master TOC Return to Section TOC 3.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-63 TROUBLESHOOTING & REPAIR OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) 6. Using 7/16” wrench remove the top and bottom mounting bolts and associated washers from the diode module to be replaced. 13. Run the center cap screw in by hand until it makes contact with the surface of the module. Do not torque down yet! 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-64 NOTES INVERTEC V250-S F-64
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-65 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-66 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) cable ties. Be sure to note the direction that the leads are threaded through the current transformer. Upon reassembly the leads must be threaded through correctly. PROCEDURE 1. Remove input power to the V250-S. 2. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. Return to Master TOC Return to Section TOC 3.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-67 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) MAIN TRANSFORMER SECONDARY LEADS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Figure F.21 Main Transformer Left Side 6. Disconnect and clear the shunt sensing leads from the control board (plug J4). 7.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-68 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) MAIN TRANSFORMER LOCKING MOUNTING TABS MAIN TRANSFORMER MOUNTING SCREWS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Figure F.22 Main Transformer Mountings 14.
Return to Master TOC Return to Section TOC F-69 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES BELOW 10150) (continued) 22. Reassemble the shunt assembly to the negative output terminal. Take note of the by-pass connection on the negative terminal. Clear leads and install any necessary cable ties. 23. Connect the two thermostat leads. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 24.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-70 NOTES INVERTEC V250-S F-70
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-71 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment could result in danger to the technician or the machine operator and will invalidate your factory warranty.
Return to Master TOC Return to Section TOC F-72 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) rent transformer. Cut any necessary cable ties. Be sure to note the direction that the leads are threaded through the current transformer. Upon reassembly the leads must be threaded correctly. PROCEDURE 1. Remove input power to the V250-S. Return to Master TOC Return to Section TOC 2.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-73 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) MAIN TRANSFORMER SECONDARY LEADS Return to Master TOC Return to Section TOC Figure F.24 Main Transformer Left Side 7. Disconnect the thermostat leads from the thermostat mounted on the shunt assembly. 8. With the 3/4” wrench remove the shunt assembly from the negative output terminal.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-74 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) MAIN TRANSFORMER LOCKING MOUNTING TABS MAIN TRANSFORMER MOUNTING SCREWS Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Figure F.25 Main Transformer Mountings 14.
Return to Master TOC Return to Section TOC F-75 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT (MACHINE CODES ABOVE 10150) (continued) 21. With the 3/4” wrench assemble the positive output lead to the positive output terminal. Return to Master TOC Return to Section TOC Take note of the by-pass connection on the positive output terminal. 22. Reassemble the shunt assembly to the negative output terminal. Take note of the by-pass connection on the negative terminal.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-76 NOTES INVERTEC V250-S F-76
Return to Master TOC Return to Section TOC F-77 F-77 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Should a machine under test be rejected for any reason requiring the removal of any mechanical part that could affect the machine’s electrical characteristics, or if any electrical components are repaired or replaced, the machine must be retested.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-78 NOTES INVERTEC V250-S F-78
ELECTRICAL DIAGRAMS Electrical Diagram Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section G Wiring Diagram (Codes 10102, 10103) . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Wiring Diagram (Codes 10187, 10188) . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 Control PC Board (G2666) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4 Power PC Board (G2684) Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES INVERTEC V250-S
Wiring Diagram (Codes 10102, 10103) L2 RIGHT 204 OUTSIDE S 1600/450 RECONNECT SWITCH 203A 203A 203A 207 I - 202 201 203 202A 203 202 POWER BOARD S1 207 Return to Master TOC R INPUT PER N.A. U TP1 A TP3 W A F D9 B V TP2 B H1 H1 BRIDGE J6 D C 209 209 D5, D6, D7 S F TP4 205 205 Y 208 Y I F S S F FRONT A S BACK S INSIDE 208 FRONT 308 2 307 3 310 4 311 5 313 6 309 D2, D3, D4 .
Wiring Diagram (Codes 10187, 10188) L2 RIGHT 204 206 OUTSIDE S 1600/450 RECONNECT SWITCH 203A 203A 203A 207 I - 202 201 201 203 202 POWER BOARD S1 207 Return to Master TOC TP3 W A F D9 B V TP2 B A - D C 209 209 208 208 J6 TP6 TP4 Y I S S F S FRONT AUX.
G-4 ELECTRICAL DIAGRAMS Control PC Board (G2666) Layout ITEM PART NO. IDENTIFICATION R109 R102 R98 C48 R103 R101 C47 R34 R100 R43 R64 D36 D41 R99 R96 R97 R94 G2666 C44 D40 R91 DZ10 R89 C43 J4 R105 R90 C50 R95 R86 C51 R104 REQ'D CONTROL P.C.
Return to Master TOC Return to Section TOC G-5 Power PC Board (G2684) Layout G2684 REQ'D ITEM PART NO IDENTIFICATION B205 B208 B209 B204 B201 Return to Master TOC POWER P.C. BD.
+15V +15V R29 R48 100V D13 R108 C21 OSC INH 14 4 OUT 1 5 DECODE 13 OUT 2 D 12 R35 6 8 BY-PASS C 11 47.5K 7 CLOCK INH B 10 50V 8 V SS +15V A R5 D32 Q4 C49 2700p 2.94K 2700p 300V .1 +IFB D9 R6 R8 1N4936 C24 PRIMARY CURRENT o 1.50K Vref .022 C42 1 X9 .1 1N4936 1 R27 R25 26.7 26.7 221 1N4936 TEST PT B D16 14 X8 12 2.21K DETECTOR R54 R83 .1 50V R68 OPEN CIRCUIT C41 Test Pt A 26.7K 1.8 40V C27 1 C17 33.2K 35V 1.
.022 .0047 50V 1000V BYT12P600 (NOMINAL) 2500 5W BLEEDER 150K 150K RESISTORS FILTER CAPACITOR 15.0K 2500 5W +15V S 15V 1.00K R42 1.00K 1.00K C8 1.00K 50V C9 15V +15V .0047 1W 204 TRANSFORMER C PRIMARY BYT12P600 5W FILTER CAPACITOR R51 R73 .0047 L 9304 15V 1.00K 1.00K R66 1.00K R64 R63 1.00K R65 1W DZ14 C11 .0047 50V E G 5W 1.82K D5 15.0K R78 J6 L 9304 SHT. NO. V250-S POWER F.V. TYPE 4 475 1 5 OCI2 10K TO CONTROL BD.