Lincoln Electric INVERTEC V250-S User's Manual

SVM124-A
INVERTEC V250-S
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July, 1996
For use with machine Code Numbers 10102 to 10188
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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. And, most
importantly, think before you act
and be careful.
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SERVICE MANUAL
World's Leader in Welding and Cutting Products
Premier Manufacturer of Industrial Motors
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
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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. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
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Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers
and devices in position and in good
repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
____________________________________________________
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1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan. Do not attempt
to override the governor or idler by pushing on the throttle
control rods while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
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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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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ii
SAFETY
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
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5.e. Also see item 1.b.
Mar ‘95
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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. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
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6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
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iii
SAFETY
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
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Mar ‘95
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iv
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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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
Mar. ‘93
vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
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PAGE
INSTALLATION .......................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS ..................................................................................................A-2
SAFETY PRECAUTIONS ............................................................................................................A-3
SELECT SUITABLE LOCATION..................................................................................................A-3
INPUT CONNECTIONS ...............................................................................................................A-3
INPUT VOLTAGE RECONNECT PROCEDURE.........................................................................A-4
OUTPUT CONNECTIONS ...........................................................................................................A-5
OPERATION
.......................................................................................................................SECTION B
SAFETY INSTRUCTIONS ...........................................................................................................B-2
GENERAL DESCRIPTION...........................................................................................................B-2
CONTROLS AND SETTINGS......................................................................................................B-3
CONSTANT CURRENT PROCESSES........................................................................................B-4
PARALLEL OPERATION .............................................................................................................B-5
OVERLOAD PROTECTION.........................................................................................................B-5
THERMAL PROTECTION............................................................................................................B-5
ACCESSORIES .......................................................................................................................SECTION C
OPTIONS / ACCESSORIES ........................................................................................................C-2
CABLE PLUGS......................................................................................................................C-2
REMOTE CONTROLS ..........................................................................................................C-2
MAINTENANCE .......................................................................................................................SECTION D
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE.........................................................D-2
ROUTINE MAINTENANCE..........................................................................................................D-3
FILTER CAPACITOR CONDITIONING ......................................................................................D-3
LOCATION OF MAINTENANCE COMPONENTS.......................................................................D-4
THEORY OF OPERATION .........................................................................................................SECTION E
GENERAL DESCRIPTION...........................................................................................................E-2
INPUT LINE VOLTAGE................................................................................................................E-2
PRE-CHARGE AND PROTECTION ............................................................................................E-3
MAIN TRANSFORMER................................................................................................................E-4
OUTPUT RECTIFICATION AND CONTROL...............................................................................E-5
PROTECTION CIRCUITS............................................................................................................E-6
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION............................................E-7
PULSE WIDTH MODULATION (PWM)........................................................................................E-8
TROUBLESHOOTING ................................................................................................................SECTION F
HOW TO USE TROUBLESHOOTING GUIDE ......................................................................F-2
PC BOARD TROUBLESHOOTING PROCEDURES.............................................................F-3
TROUBLESHOOTING GUIDE...............................................................................................F-4
TEST PROCEDURES..........................................................................................................F-11
REPAIR AND REPLACEMENT PROCEDURES.................................................................F-43
RETEST AFTER REPAIR....................................................................................................F-77
ELECTRICAL DIAGRAMS.........................................................................................................SECTION G
PARTS MANUAL ................................................................................................................................P-244
INVERTEC V250-S
INSTALLATION
SECTION-A-1
TABLE OF CONTENTS
-INSTALLATION SECTIONTECHNICAL SPECIFICATIONS ..................................................................................................A-2
SAFETY PRECAUTIONS ............................................................................................................A-3
SELECT SUITABLE LOCATION..................................................................................................A-3
STACKING.............................................................................................................................A-3
TILTING .................................................................................................................................A-3
HIGH FREQUENCY PRECAUTIONS ...................................................................................A-3
INPUT CONNECTIONS ...............................................................................................................A-3
GROUND CONNECTION......................................................................................................A-3
INPUT SUPPLY CONNECTIONS .........................................................................................A-3
POWER INPUT CONNECTION FOR 60HZ MACHINES ......................................................A-3
POWER INPUT CONNECTION FOR 50/60 HZ MACHINES ................................................A-4
INPUT FUSE AND SUPPLY WIRE .......................................................................................A-4
INPUT VOLTAGE RECONNECT PROCEDURE.........................................................................A-4
OUTPUT CONNECTIONS ...........................................................................................................A-5
REMOTE CONTROL RECEPTACLE ....................................................................................A-5
OUTPUT CABLES .................................................................................................................A-5
QUICK DISCONNECT PLUGS..............................................................................................A-5
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SECTION-A-1
INVERTEC V250-S
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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
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(1)
Duty Cycle
35% Duty Cycle
60% Duty Cycle
100% Duty Cycle
35% Duty Cycle
60% Duty Cycle
100% Duty Cycle
SINGLE PHASE
Volts at
Rated Amps
30
28-32
26.5
28†-30
29-32
26.5
Amps
250
200
165
250
200
165
Model
60Hz
60Hz
60Hz
50/60Hz
50/60Hz
50/60Hz
(1)
Duty Cycle
35% Duty Cycle
60% Duty Cycle
100% Duty Cycle
35% Duty Cycle
60% Duty Cycle
100% Duty Cycle
Volts at
Rated Amps
27†-30
28-32
26.5
26†-30
28-32
26.5
Amps
250
200
165
250
200
165
Model
60Hz
60Hz
60Hz
50/60Hz
50/60Hz
50/60Hz
OUTPUT
THREE PHASE
Welding
Current Range
1-250 Amps
SINGLE PHASE
Constant Open
Circuit Voltage
65-80 VDC
Welding
Current Range
1-250 Amps
Constant Open
Circuit Voltage
65-80 VDC
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RECOMMENDED INPUT WIRE AND FUSE SIZES
THREE PHASE
SINGLE PHASE
Input
Voltage
Frequency(2)
Fuse
Input
(Superlag) Ampere
or
Rating
Breaker
on
Size
Nameplate
Type 75°C
Copper
Wire in
Conduit
AWG (IEC)
Sizes
Type 75°C
Copper
Ground
Wire in
Conduit
AWG (IEC)
Sizes
Input
Voltage
Frequency(2)
Fuse
Input
(Superlag) Ampere
or
Rating
Breaker
on
Size
Nameplate
Type 75°C
Copper
Wire in
Conduit
AWG (IEC)
Sizes
Type 75°C
Copper
Ground
Wire in
Conduit
AWG (IEC)
Sizes
208/60
230/60
460/60
50
50
30
34
32
16
10 (6mm2)
10(6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
208/60(3)
230/60(3)
460/60
80
80
40
59
57
29
8 (10mm2)
8 (10mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
200/50/60
220/50/60
400/50/60
440/50/60
50
50
30
30
35
33
18
17
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
200/50/60
220/50/60
400/50/60
440/50/60
80
80
40
40
58
58
30
30
8 (16mm2)
8 (16mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
10 (6mm2)
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PHYSICAL DIMENSIONS
Height
15.0 in.
Width
9.1 in.
Depth
19.7 in.
Weight
36 lbs.
381 mm
231 mm
500 mm
17 Kg
(1) Based on a 10 min. period.
(2) Input voltage must be within ±10% of rated value.
(3) For 1 phase use on 208 or 230 VAC input with output usage above 175A/60% or 200A/35%, the #10 input line cord supplied with the unit should be changed to a
#8 or larger conductor cord.
(†) 200 & 208VAC input may not meet NEMA/IEC specifications at 250 Amps.
INVERTEC V250-S
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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.
• Turn the input power off at the fuse
box before working on 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.
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• 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.
---------------------------------------------------------------------
SELECT SUITABLE LOCATION
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• The machine must be located where there is free circulation 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.
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 instructions. 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 provide 600V insulation.
STACKING
V250-S’s cannot be stacked.
TILTING
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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.
INPUT SUPPLY CONNECTIONS
The Invertec V250-S will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life
and reliable operation.
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GROUND CONNECTION
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.
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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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.
If 440 or 460 VAC is the desired input, then the
machine may be connected to the power system without any setup required inside the reconnect door.
However, verify the connection with the following procedure. For other voltages refer to the instructions
located on the Reconnect Panel Access Door or follow the instructions below.
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The Invertec V250-S 50/60 Hz machine is supplied
with one cord connector. The cord connector provides
a strain relief for the input power cord as it passes it
through the rear access hole. The cord connector is
designed for a cord diameter of 7.9 to 27.2mm (.310
to 1.070 in).
CAUTION
Failure to follow these instructions can cause immediate failure of components within the welder.
------------------------------------------------------------------------
Strip away outer jacket of cord, trim fillers and insert
conductors through cord connector. The jacketed portion of the cord must go through the cord connector.
Tighten both connector screws.
1. Open the access door on the right side of the
machine.
INPUT FUSE AND SUPPLY WIRE
2. For 200-230: Position the large switch to 200-230.
For 380-460: Position the large switch to 380-460.
Refer to the Technical Specifications page at the
beginning of this chapter for the proper fuse sizes and
supply cable sizes.
3. Move the “A” lead to the appropriate terminal.
Refer to figure A.1 below.
• Fuse the input circuit with recommended super lag
fuses or delay type circuit breakers.
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• Install the proper fuse in the fuse holder in the main
disconnect panel.
RECONNECT PROCEDURE
. Disconnect input power before
1. BE SURE POWER SWITCH IS OFF.
inspecting or servicing machine.
.
2. CONNECT LEAD 'A' TO DESIRED
INPUT VOLTAGE RANGE.
.
440-460V
.
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A-4
INSTALLATION
'A'
380-415V
220-230V
Do not operate with wraparound
removed.
Do not touch electrically live parts.
Only qualified persons should install,
use or service this equipment.
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
200-208V
REPLACE WITH SPECIFIED FUSE.
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3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
VOLTAGE=380-460V
THE LINCOLN ELECTRIC CO.
CLEVELAND, OHIO U.S.A.
VOLTAGE=200-230V
A
Figure A.1 Input Voltage Reconnect Instructions
INVERTEC V250-S
S21230
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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.
THERMAL
HOT START
4
5
6
7
3
A
6 PIN
REMOTE
RECEPTACLE
85
50
15
REMOTE
LOCAL
9
1
0
170
2. Slide rubber boot onto cable end. The boot end
may be trimmed to match the cable diameter.
Soap or other lubricant will help to slide the boot
over the cable.
8
2
120
OUTPUT
10
ARC FORCE
230
1
4
5
6
7
3
250
8
2
9
1
0
10
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BOOT
¤
WELDING CABLE
INVERTEC V250-S
-
+
I
S
25 mm
TRIM
1 in.
O
OUTPUT TERMINALS
3.
Slide the copper tube into the brass plug.
4.
Insert cable into copper tube.
5.
Tighten set screw to collapse copper tube. Screw
must apply pressure against welding cable. The
top of the set screw will be well below the surface
of the brass plug after tightening.
FIGURE A.2 OUTPUT CONNECTIONS
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REMOTE CONTROL RECEPTACLE
Remote control (K857), Arc start switch (K814), Hand
amptrol (K963) and Foot amptrol (K870) connect
directly to 6 pin amphenol on the front of the unit.
SET SCREW
OUTPUT CABLES
Select the output cable size based on Table A.1.
BRASS PLUG
COPPER TUBE
TABLE A.1
Cable Sizes for Combined Length of Electrode and
Work Cable ( Copper Cable Rated at 75°C).
Cable Size
1/0 (50mm2)
2/0 (70mm2)
6.
Slide rubber boot over brass plug. The rubber
boot must be positioned to completely cover all
electrical surfaces after the plug is locked into the
receptacle.
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Length
up to 150 ft.(46m)
up to 250 ft.(72m)
INVERTEC V250-S
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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 ........................................................................................................B-2
LIMITATIONS ........................................................................................................................B-2
CONTROLS AND SETTINGS......................................................................................................B-3
CONSTANT CURRENT PROCESSES........................................................................................B-4
MANUAL ARC WELDING (STICK)........................................................................................B-4
AIR CARBON ARC CUTTING ...............................................................................................B-4
TIG WELDING .......................................................................................................................B-4
PARALLEL OPERATION .............................................................................................................B-5
OVERLOAD PROTECTION.........................................................................................................B-5
THERMAL PROTECTION............................................................................................................B-5
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SECTION-B-1
INVERTEC V250-S
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B-2
OPERATION
Read and understand this entire section before
operating your machine.
WARNING
ELECTRIC SHOCK can kill.
OPERATIONAL FEATURES
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• 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). It is also rated at
165 amps, 100% duty cycle, and 200 amps, 60% duty
cycle.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
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.
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
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The Invertec V250-S provides continuous total range
output current adjustment, selectable welding modes
and local or remote output control. Welding characteristics can be controlled via an arc force control.
Additionally, starting characteristics can be adjusted
via a “hot start” control.
____________________________________
____________________________________
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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
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held combustibles.
____________________________________
ARC RAYS
can burn.
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• Wear eye, ear and body
protection.
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B-2
____________________________________
Only qualified personnel should operate this equipment. Observe all safety information throughout this
manual.
INVERTEC V250-S
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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.
4
8
SMAW
SOFT
SMAW
CRISP
GTAW
THERMAL
HOT START
4
2
6
7
85
3
15
LOCAL
0
170
5
9
1
50
REMOTE
8
2
120
OUTPUT
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5
3
A
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B-3
OPERATION
10
ARC FORCE
230
1
4
5
6
7
3
250
8
2
6
9
1
0
10
®
INVERTEC V250-S
+
-
I
S
1
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O
7
1. Power Switch - Place the lever in the “ON” position
to energize the machine. When the power is on, the
fan will operate and the output will be energized in
SMAW modes. GTAW mode requires remote trigger to energize the output.
2. Output Control - This controls the output current.
Control is provided over the entire output range of
the power source with 1 turn of the control knob.
This control may be adjusted while under load to
change power source output. When using remote
control this function becomes the limit setting.
3. Local/Remote Switch - Place in the “LOCAL” position to allow output adjustment at the machine.
Place in the “REMOTE” position to allow output
adjustment at remote pot or amptrol. In Remote, the
machine output control pot is the limit setting for
remote control.
4. Mode Switch
GTAW Optimized for touch start use. Triggering at
amphenol is required using an Arc Start Switch,
Amptrol or similar means. Short circuit current is
limited to approximately 25 amps to aid in touch
starting.
CC Soft Best for EXX18 thru EXX28 stick electrodes. Output energized when machine is on.
CC Crisp
Use this mode for stick welding with
EXX10 thru EXX14 electrodes. Output energized
when machine is on.
5. Hot Start - Controls the amount of starting energy
in SMAW.
INVERTEC V250-S
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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.
RECOMMENDED ARC FORCE/INDUCTANCE
SETTINGS FOR SELECTED APPLICATIONS
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CONSTANT CURRENT PROCESSES
MANUAL ARC WELDING (STICK)
The Invertec may be utilized as a manual DC arc
welder with the electrode cable, work cable, and electrode holder being the only equipment required.
AIR CARBON ARC CUTTING
FULL RANGE IS 1-10. 1 is VERY SOFT,
10 IS VERY CRISP
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B-4
Nominal
Setting
Recommended
Adjustment Range
EXX18 thru
EXX28 stick
5
1 (gentle, may stick) to 9
(forceful, more spatter)
EXX10 thru
EXX14 stick
6
3 to 10
Air Carbon Arc
Cutting
1
None
Mode
Process
CC SMAW 1
(soft)
CC SMAW 2
(crisp)
Air carbon arc cutting may be performed with the
Invertec within its output rating using 5/32" (3.9mm)
and 3/16" (4.7mm) diameter carbon rods. Output
cables, an air carbon arc electrode cable assembly,
and a source of compressed air are required.
NOTE:
1. Best performance will be at settings of 200 amps
and below.
2. The electronic protection circuit in the V250S will
limit the current to approximately 290 amps.
7. Output Terminals - These quick disconnect terminals provide connection points for the electrode and
work cables. Refer to Output Connections in the
Installation chapter for proper cable sizes. For
positive polarity welding connect the electrode
cable to the positive terminal and the work cable to
the negative terminal. To weld negative polarity
reverse the electrode and work cables.
8. Thermal Shutdown Indicator - This light will illuminate if an internal thermostat has been activated.
Machine output will return after the internal
components have returned to a normal operating
temperature. See Thermal Protection later in this
chapter.
TIG WELDING
The V250S is capable of touch start TIG welding. An
electrode cable, work cable, Arc Start Switch or
Amptrol, TIG torch, and gas supply with regulator are
required. Refer to Accessories section of this manual.
Touch starting is done as follows:
1. Place the shield cup edge on the work piece.
2. Rock the tungsten down to touch.
3. Trigger the output.
4. Gently rock back the tungsten from the workpiece.
Note: The short circuit current is limited to 25 amps to
aid in touch starting. Panel output control
becomes the current limit setting when in
remote control
INVERTEC V250-S
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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. In general, more than two machines in parallel will not be effective due to the voltage requirements of procedures in that power range.
To set machine outputs, start with output control pots
and arc force pots in identical positions. Adjust outputs and arc forces to maintain current sharing while
establishing the proper output current.
OVERLOAD PROTECTION
The machine is electrically protected from producing
high output currents. Should the output current
exceed 290A, an electronic protection circuit will
reduce the current to less than 200A. The machine
will continue to produce this low current until the protection circuit is reset. Reset occurs when the output
load is removed.
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THERMAL PROTECTION
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostats will prevent output voltage or current.
Thermostats are self-resetting once the machine cools
sufficiently. If the thermostat shutdown was caused by
excessive output or duty cycle and the fan is operating
normally, the Power Switch may be left on and the
reset should occur within a 15 minute period. If the fan
is not turning or the air intake louvers were obstructed,
then the power must be switched off for 15 minutes in
order to reset. The fan problem or air obstruction must
also be corrected.
INVERTEC V250-S
B-5
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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 .......................................................................................................................C-2
REMOTE CONTROLS ..........................................................................................................C-2
K857.............................................................................................................................C-2
K963 ............................................................................................................................C-2
K870.............................................................................................................................C-2
K814 ............................................................................................................................C-2
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SECTION C-1
INVERTEC V250-S
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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.
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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. The Hand Amptrol connects
directly to the 6 pin Amphenol.
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K870 - Foot Amptrol tm for TIG welding. When the
V250-S’s Output Control is in the “REMOTE” position,
the foot Amptrol energizes the output and controls the
output remotely. The Hand Amptrol connects directly
to the 6 pin Amphenol.
K814 - Arc Start Switch. Energizes the output for TIG
welding if remote output control of the amperage is
not desired. When using the Arc Start Switch set the
Output Control to the “LOCAL” position.
INVERTEC V250-S
C-2
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.......................................................................D-4
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SECTION D-1
INVERTEC V250-S
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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. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
5. Locate the four capacitor terminals (large hex head
cap screws) shown in Figure D.1. One pair at the
top and one pair at the bottom of the Power Board.
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor
leads across the two capacitor terminals. Hold
resistor in place for 10 seconds. DO NOT TOUCH
CAPACITOR TERMINALS WITH YOUR BARE
HANDS.
1. Turn off input power or disconnect input power
lines.
7. Repeat discharge procedure for the capacitor on
other two terminals.
2. Remove the 5/16" hex head screws from the side
and top of the machine and remove wrap-around
machine cover.
8. Check voltage across terminals of all capacitors
with a DC voltmeter. Polarity of capacitor terminals
is marked on PC board above terminals. Voltage
should be zero. If any voltage remains, repeat this
capacitor discharge procedure.
3. Be careful not to make contact with the capacitor
terminals that are located in the top and bottom of
the Power Board.
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FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
POWER
BOARD
UPPER
CAPACITOR TERMINALS
LOWER
CAPACITOR
TERMINALS
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POWER
RESISTOR
RIGHT SIDE OF MACHINE
INSULATED
GLOVES
INVERTEC V250-S
INSULATED
PLIERS
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D-3
ROUTINE MAINTENANCE
1.
2.
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3.
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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).
Keeping the machine clean will result in cooler
operation and higher reliability. Be sure to clean
the following areas with a low pressure air
stream. See figure D.2 for component locations.
•
Power and control printed circuit boards
•
Power switch
•
Main transformer
•
Input rectifier
•
Heat sink fins
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• Output Terminals
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FILTER CAPACITOR
CONDITIONING
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%. Reset occurs about 3% lower (230/460
VAC +12%).
On new installations, the protection circuit may also
prevent output providing all these circumstances are
met:
1. Machine is connected for 380-415 or 440-460
VAC input.
2. Machine did not have power applied for many
months.
3. Machine will not produce output when power is
first switched on.
If these circumstances apply, the proper action is to
switch the machine on and let it idle for up to 30 minutes. This is required to condition the filter capacitors
after an extended storage time. The protection circuit
will automatically reset once the capacitor conditioning
and resultant voltage levels are acceptable. It may be
necessary to turn the power switch off and back on
again after this period.
• Input Filter Capacitors
4. Examine capacitors for leakage or oozing. Replace
if needed.
5.
D-3
Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case
in good condition to ensure that high voltage
parts are protected and correct spacings are
maintained. All external sheet metal screws must
be in place to assure case strength and electrical
ground continuity.
6. Check electrical ground continuity. Using an ohmmeter, measure resistance between either output
terminal and an unpainted surface of the machine
case. (See Figure D.2 for locations.) Meter reading
should be 500,000 ohms or more. If meter reading
is less than 500,000 ohms, check for electrical
components that are not properly insulated from
the case. Correct insulation if needed.
7. Replace machine cover and screws.
INVERTEC V250-S
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D-4
D-4
MAINTENANCE
FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
INPUT RECTIFIER
CONTROL PC BOARD
POWER PC BOARD
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POWER SWITCH
COOLING FANS
OUTPUT TERMINALS
OUTPUT RECTIFIER
HEATSINK FINS
MAIN TRANSFORMER
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AUXILIARY TRANSFORMER
INVERTEC V250-S
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................................................................................................................E-4
OUTPUT RECTIFICATION AND CONTROL...............................................................................E-5
PROTECTION CIRCUITS............................................................................................................E-6
INSULATED GATE BIPOLAR TRANSISTOR (IGBT) OPERATION............................................E-7
PULSE WIDTH MODULATION (PWM)........................................................................................E-8
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E-1
INVERTEC V250-S
E-1
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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.1 - INPUT VOLTAGE CIRCUITS
MAIN
TRANSFORMER
POWER BOARD
CR1
RELAY
INPUT
RECTIFIER
INPUT
LINE
SWITCH
IGBT
POSITIVE
OUTPUT
TERMINAL
CAPACITOR
R
E
C
O
N
N
E
C
T
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E-2
THEORY OF OPERATION
IGBT
SHUNT
IGBT
CURRENT
TRANSFORMER
S
W
I
T
C
H
CAPACITOR
F
E
E
D
B
A
C
K
IGBT
"A"
L
E
A
D
O
V
E
R
V
O
L
T
A
G
E
FAN
MOTORS
THERMOSTATS
IGBT GATE SIGNALS
PROTECTION SIGNAL
CR1 RELAY DRIVE SIGNAL
CONTROL BOARD
F
E
E
D
B
A
C
K
NEGATIVE
OUTPUT
TERMINAL
THERMAL
LIGHT
18VAC
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AUXILIARY
TRANSFORMER
REMOTE
RECEPTACLE
OUTPUT STRIKE
ARC
MODE LOCAL/
CONTROL CONTROL FORCE SWITCH REMOTE
SWITCH
CONTROL
INPUT LINE VOLTAGE
The single-phase or three-phase input power of 208,
230 or 460 volts AC is connected to the machine,
through a line switch located on the front panel.
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A reconnect panel and switch allows the user to configure the machine for either a low or high input voltage and also connect the auxiliary transformer for the
appropriate input voltage.
The auxiliary transformer develops the appropriate AC
voltages to operate the cooling fans and the control
board.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
INVERTEC V250-S
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E-3
FIGURE E.2 PROTECTION AND PRE-CHARGE CIRCUITS
CR1
RELAY
INPUT
RECTIFIER
INPUT
LINE
SWITCH
IGBT
POSITIVE
OUTPUT
TERMINAL
CAPACITOR
IGBT
SHUNT
IGBT
CURRENT
TRANSFORMER
S
W
I
T
C
H
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MAIN
TRANSFORMER
POWER BOARD
R
E
C
O
N
N
E
C
T
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E-3
THEORY OF OPERATION
CAPACITOR
F
E
E
D
B
A
C
K
IGBT
"A"
L
E
A
D
O
V
E
R
V
O
L
T
A
G
E
FAN
MOTORS
THERMOSTATS
IGBT GATE SIGNALS
PROTECTION SIGNAL
CR1 RELAY DRIVE SIGNAL
CONTROL BOARD
F
E
E
D
B
A
C
K
NEGATIVE
OUTPUT
TERMINAL
THERMAL
LIGHT
18VAC
AUXILIARY
TRANSFORMER
REMOTE
RECEPTACLE
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OUTPUT STRIKE
ARC
MODE LOCAL/
CONTROL CONTROL FORCE SWITCH REMOTE
SWITCH
CONTROL
PRECHARGE AND PROTECTION
The input voltage is rectified and the DC voltage is
applied, through the reconnect switch, to the power
board. The power board contains precharging circuitry for the safe charging of the input filter capacitors.
Once the capacitors are precharged and balanced the
control board activates the CR1 input relay which connects full input power to the filter capacitors. When
the filter capacitors are fully charged they act as
power supplies for the IGBT switching circuit. The
Insulated Gate Bipolar Transistors supply the main
transformer primary windings with DC current flow.
See IGBT Operation Discussion and diagrams in
this section.
The power board also monitors the filter capacitors for
voltage balance and/or overvoltage and, if either
should occur, sends the appropriate signal to the control board to deactivate the CR1 input relay. The
machine output will also be disabled.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
INVERTEC V250-S
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E-4
FIGURE E.3 MAIN TRANSFORMER
CR1
RELAY
INPUT
RECTIFIER
INPUT
LINE
SWITCH
IGBT
POSITIVE
OUTPUT
TERMINAL
CAPACITOR
IGBT
SHUNT
IGBT
CURRENT
TRANSFORMER
S
W
I
T
C
H
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MAIN
TRANSFORMER
POWER BOARD
R
E
C
O
N
N
E
C
T
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E-4
THEORY OF OPERATION
CAPACITOR
F
E
E
D
B
A
C
K
IGBT
"A"
L
E
A
D
O
V
E
R
V
O
L
T
A
G
E
FAN
MOTORS
THERMOSTATS
IGBT GATE SIGNALS
PROTECTION SIGNAL
CR1 RELAY DRIVE SIGNAL
CONTROL BOARD
F
E
E
D
B
A
C
K
NEGATIVE
OUTPUT
TERMINAL
THERMAL
LIGHT
18VAC
AUXILIARY
TRANSFORMER
REMOTE
RECEPTACLE
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OUTPUT STRIKE
ARC
MODE LOCAL/
CONTROL CONTROL FORCE SWITCH REMOTE
SWITCH
CONTROL
MAIN TRANSFORMER
Each IGBT pair acts as a switch assembly. Each
assembly feeds a separate, oppositely wound primary
winding of the main transformer. The reverse directions of current flow through the main transformer primaries and the offset timing of the IGBT pairs induce
an AC square wave output signal at the secondary of
the main transformer.
The DC current flow through each primary winding is
redirected or “clamped” back to each respective filter
capacitor when the IGBTs are turned off. This is
needed due to the inductance of the transformer primary winding.
The primary currents also pass through the current
transformer which sends a signal to the control board.
If the primary currents are not equal the control board
compensates by adjusting the IGBT gate signals.
The firing of both IGBT pairs occurs during halves of
the 50 microsecond intervals, creating a constant 20
KHZ output.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
INVERTEC V250-S
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E-5
FIGURE E.4 OUTPUT RECTIFICATION AND CONTROL
CR1
RELAY
INPUT
RECTIFIER
INPUT
LINE
SWITCH
IGBT
POSITIVE
OUTPUT
TERMINAL
CAPACITOR
IGBT
SHUNT
IGBT
CURRENT
TRANSFORMER
S
W
I
T
C
H
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MAIN
TRANSFORMER
POWER BOARD
R
E
C
O
N
N
E
C
T
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E-5
THEORY OF OPERATION
CAPACITOR
F
E
E
D
B
A
C
K
IGBT
"A"
L
E
A
D
O
V
E
R
V
O
L
T
A
G
E
FAN
MOTORS
THERMOSTATS
IGBT GATE SIGNALS
PROTECTION SIGNAL
CR1 RELAY DRIVE SIGNAL
CONTROL BOARD
F
E
E
D
B
A
C
K
NEGATIVE
OUTPUT
TERMINAL
THERMAL
LIGHT
18VAC
AUXILIARY
TRANSFORMER
REMOTE
RECEPTACLE
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OUTPUT STRIKE
ARC
MODE LOCAL/
CONTROL CONTROL FORCE SWITCH REMOTE
SWITCH
CONTROL
OUTPUT RECTIFICATION
AND CONTROL
The AC output from the main transformer secondary
is rectified to a DC output and applied to the output
terminals. Output voltage and current feedback information, which is fed to the control board, is sensed at
the output terminals and shunt. The control board
monitors the panel controls and remote control receptacle and compares these commands to the feedback
information to determine how the output should be
controlled to optimized welding results. The control
board controls the IGBT switching through pulse width
modulation circuitry. See IGBT Operation Discussion
in this section.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
INVERTEC V250-S
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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. Should the output current
exceed 290 amps, an electronic protection circuit will
reduce the current to less than 200 amps. Lincoln
Electric refers to this current reduction as “Fold Back”.
The machine will continue to produce this low current
until the protection circuit is reset. Reset occurs when
the output load is removed.
Thermostats protect the machine from excessive
operating temperatures. Excessive temperatures may
be caused by a lack of cooling air or operating the
machine beyond the duty cycle and output rating. If
excessive operating temperature should occur, the
thermostat will prevent output voltage or current and
the thermal indicator light will glow.
A protection circuit is included to monitor the voltage
across the input filter capacitors. In the event that the
capacitor voltage is too high, the protection circuit will
prevent output.
On new installations, the protection circuit may prevent output, due to unbalanced capacitor leakages,
providing the following circumstances are met:
Thermostats are self-resetting once the machine cools
sufficiently. If the thermostat shutdown was caused
be excessive output or duty cycle and the fan is operating normally, the power switch may be left on and
the reset should occur within 15 minute period. If the
fan is not turning or the air intake louvers were
obstructed, then the power must be switched off for 15
minutes in order to reset. The fan problem or air
obstruction must be corrected.
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1. Machine is connected for 380 - 460VAC input.
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E-6
2. Machine did not have power applied for many
months.
3. Improper connections.
4. Internal component damage.
NOTE: Unshaded areas of block logic diagrams are the subject of discussion.
INVERTEC V250-S
E-7
E-7
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INSULATED GATE BIPOLAR
TRANSISTOR (IGBT) OPERATION
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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. There
is no gate signal, zero volts relative to the source, and
therefore, no current flow. The drain terminal of the
IGBT may be connected to a voltage supply; but since
there is no conduction the circuit will not supply current to components connected to the source. The circuit is turned off like a light switch in the OFF position.
source, is applied to the gate terminal of the IGBT, it
is capable of conducting current. A voltage supply
connected to the drain terminal will allow the IGBT to
conduct and supply current to circuit components
coupled to the source. Current will flow through the
conducting IGBT to downstream components as long
as the positive gate signal is present. This is similar
to turning ON a light switch.
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FIGURE E.6 IGBT OPERATION
POSITIVE
VOLTAGE
APPLIED
SOURCE
n+
GATE
n+
n+
GATE
n+
p
BODY REGION
p
BODY REGION
n-
DRAIN DRIFT REGION
n-
DRAIN DRIFT REGION
n+
BUFFER LAYER
n+
BUFFER LAYER
p+
INJECTING LAYER
p+
INJECTING LAYER
DRAIN
DRAIN
B. ACTIVE
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A. PASSIVE
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SOURCE
INVERTEC V250-S
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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.
The positive portion of the signal represents one IGBT
group1 conducting for 1 microsecond. The negative
portion is the other IGBT group1. The dwell time (off
time) is 48 microseconds (both IGBT groups off).
Since only 2 microseconds of the 50-microsecond
time period is devoted to conducting, the output power
is minimized.
MINIMUM OUTPUT
MAXIMUM OUTPUT
By controlling the duration of the gate signal, the IGBT
is turned on and off for different durations during a
cycle. The top drawing below shows the minimum
output signal possible over a 50-microsecond time
period.
By holding the gate signals on for 24 microseconds
each and allowing only 2 microseconds of dwell time
(off time) during the 50-microsecond cycle, the output
is maximized. The darkened area under the top curve
can be compared to the area under the bottom curve.
The more dark area under the curve, the more power
is present.
1
An IGBT group consists of two IGBT modules feeding one transformer primary winding.
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FIGURE E.7 TYPICAL IGBT OUTPUTS
sec
48
50
sec
sec
sec
MINIMUM OUTPUT
24 sec
24 sec
2 sec
50 sec
MAXIMUM OUTPUT
INVERTEC V250-S
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 .....................................................................................................F-4
TEST PROCEDURES
AUXILIARY TRANSFORMER TEST ...................................................................................F-11
INPUT RECTIFIER TEST ....................................................................................................F-15
POWER BOARD RESISTANCE TEST................................................................................F-19
OUTPUT DIODE TEST........................................................................................................F-23
POWER BOARD VOLTAGE TEST......................................................................................F-27
CONTROL BOARD VOLTAGE TEST..................................................................................F-31
PROTECTION CIRCUIT TEST............................................................................................F-35
CAPACITOR BALANCE TEST ............................................................................................F-39
REPAIR AND REPLACEMENT PROCEDURES
CONTROL BOARD REMOVAL AND REPLACEMENT.......................................................F-43
POWER BOARD REMOVAL AND REPLACEMENT...........................................................F-45
FILTER CAPACITOR REMOVAL AND REPLACEMENT....................................................F-49
INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT ........................................F-53
OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT ......................................F-57
(MACHINE CODES BELOW 10150)
OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT ......................................F-61
(MACHINE CODES ABOVE 10150)
MAIN TRANSFORMER REMOVAL AND REPLACEMENT ................................................F-65
(MACHINE CODES BELOW 10150)
MAIN TRANSFORMER REMOVAL AND REPLACEMENT ................................................F-71
(MACHINE CODES ABOVE 10150)
RETEST AFTER REPAIR ..........................................................................................................F-77
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SECTION F-1
INVERTEC V250-S
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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.
__________________________________________________________________________
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This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
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F-2
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes
possible symptoms that the machine may
exhibit. Find the listing that best describes
the symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED COURSE OF
ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject
component is either good or bad. If there
are a number of possible components,
check the components in the order listed to
eliminate one possibility at a time until you
locate the cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter. Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed call 216-383-2531 or 1-800-833-9353.
_____________________________________________________________
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OSCILLOSCOPE WARNING
WARNING
Do not use oscilloscopes and other test equipment which are powered by 115 VAC.
This equipment should not be used with inverter-type machines, such as Invertec
V250-S. There are high voltages present, which are “floating” off case ground (floating
ground). Connecting the ground lead of a test probe (which may be connected to the
case of the test equipment) to a high voltage potential presents a shock hazard as well
as the possibility of damage to the equipment in question.
_____________________________________________________________________
INVERTEC V250-S
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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.
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CAUTION: Sometimes machine failures
appear to be due to PC board failures. These
problems can sometimes be traced to poor
electrical connections. To avoid problems
when troubleshooting and replacing PC
boards, please use the following procedure:
1. Determine to the best of your technical
ability that the PC board is the most likely
component causing the failure symptom.
2. Check for loose connections at the PC
board to assure that the PC board is properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to
avoid static electrical damage and electrical shock. Read the warning inside the
static resistant bag and perform the following procedures:
P.C. Board can be damaged by static electricity.
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
- Remove your body’s static charge before opening
the static-shielding bag.
Wear an anti-static wrist
strap. For safety, use a 1
Meg ohm resistive cord
connected to a grounded
part of the equipment
frame.
Reusable
Container
Do Not Destroy
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_______________________________
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F-3
- If you don’t have a wrist
strap, touch an unpainted,
grounded, part of the
equipment frame. Keep touching the frame to
prevent static build-up. Be sure not to touch
any electrically live parts at the same time.
- Tools which come in contact with the P.C.
Board must be either conductive, anti-static or
static-dissipative.
INVERTEC V250-S
- Remove the P.C. Board from the staticshielding bag and place it directly into the
equipment. Don’t set the P.C. Board on or
near paper, plastic or cloth which could have
a static charge. If the P.C. Board can’t be
installed immediately, put it back in the staticshielding bag.
- If the P.C. Board uses protective shorting
jumpers, don’t remove them until installation
is complete.
- If you return a P.C. Board to The Lincoln
Electric Company for credit, it must be in the
static-shielding bag. This will prevent further
damage and allow proper failure analysis.
4. Test the machine to determine if the failure symptom has been corrected by the
replacement PC board.
NOTE: It is desirable to have a spare (known
good) PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that
all electrical components can reach their operating temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
a. If the original problem does not reappear by substituting the original
board, then the PC board was not the
problem. Continue to look for bad
connections in the control wiring harness, junction blocks, and terminal
strips.
b. If the original problem is recreated by
the substitution of the original board,
then the PC board was the problem.
Reinstall the replacement PC board
and test the machine.
6. Always indicate that this procedure was
followed when warranty reports are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
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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.
is removed.
Contact Lincoln Electric Service
Department (216)-383-2531 or
1-800-833-9353
The machine is dead - no output no fan.
1. The input power switch must be
in the ON position.
1. The power switch (S1) may be
faulty. Check or replace.
2. Make sure the input voltage is
correct for the machine.
2. Check for loose or broken leads
between the power switch (S1)
and the input rectifier D9. See
wiring diagram.
3. If the machine is set for singlephase operation, inspect to
assure that the WHITE and
3. Perform the Auxiliary
Transformer Test.
BLACK leads are connected
properly and the RED lead is not
connected and is insulated.
4. Check that the input voltage setup switch and jumper “A” (the
reconnect auxiliary jumper) are in
the proper position for the input
voltage being applied. Refer to
Input Voltage Reconnect
Procedure in the Installation
Chapter.
5. Check continuity of the 0.6-amp
slow blow fuse located on the
reconnect panel.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
INVERTEC V250-S
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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. Check for loose or broken
connections on the high current
2. The Local/Remote switch (S3)
carrying parts of the V250-S.
must be in the LOCAL position
(i.e., output diodes, output
unless a remote control device is
terminals, shunt and main
attached to the remote
transformer connections.)
receptacle.
3. Check the continuity of the
3. If the machine has not been used
normally closed thermostats and
for a long time and is connected
associated wiring. See wiring
for 380 VAC or higher, the
diagram.
capacitors may need “conditioning”. See Input Filter Capacitor 4. Perform the Output Diode Test.
Conditioning.
5. Perform the Capacitor Balance
4. The machine may be overheated.
Test.
Check the thermal indicator light.
Wait for the machine to cool and 6. Perform the Protection Circuit
the thermostats to reset.
Test.
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7. Perform the Power Board
Voltage Checks.
8. Perform the Control Board
Voltage Checks.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
INVERTEC V250-S
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F-6
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
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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. Make
and associated wiring for loose or
sure the input voltage is correct
faulty connections.
for the machine. See Input
Voltage Reconnect Procedure. 2. Check Mode Switch (S2) and
associated wiring for loose or
2. Check or replace remote control
faulty connections.
device. (If used)
3. If the machine is connected for
380VAC input or higher, perform
the Capacitor Balance Test.
4. The power board may be faulty.
Replace.
5. The control board may be faulty.
Replace.
Remote output control not
functioning. The machine operates
normally on LOCAL control.
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F-6
1. Make sure the Local/Remote
switch (S3) is in the REMOTE
position.
1. Check the Local/Remote switch
(S3) and the associated wiring.
See wiring diagram.
2. The remote control device may
be faulty. Replace.
2. Check for loose or faulty
connections at the remote control
receptacle.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
INVERTEC V250-S
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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.
heat damage. Replace any damaged components after conduct2. Install new fuses and reapply
ing the following tests.
power. If fuses open again, consult a Lincoln Authorized Field
2. Perform the Input Rectifier Test.
Service Facility.
3. Perform Power Board
Resistance Test.
4. Check the reconnect switch and
associated leads for “shorts” or
faulty wiring.
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The machine operates normally
1. Check the input voltage and input 1. Perform the Capacitor Balance
Test.
when connected for 200 - 230VAC
voltage reconnect procedures.
input. There is no output when the
See Installation Section of this
manual.
2. Perform the Protection Circuit
machine is connected to 380VAC or
Test.
higher.
3. Perform the Auxiliary
Transformer Test.
4. Perform the Power Board
Resistance Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
INVERTEC V250-S
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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.
the output current exceeds 290
amps, an electronic protection
2. The control board may be faulty.
circuit will reduce the current to
Replace.
less than 200 amps. The
machine will continue to produce
this low current until the
protection circuit is reset. Reset
occurs when the output load is
removed.
2. Check the input voltage and input
voltage reconnect procedures.
See Input Voltage Reconnect
Procedure.
3. Check for loose or faulty welding
cables.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
INVERTEC V250-S
Return to Master TOC
TROUBLESHOOTING & REPAIR
PROBLEMS
(SYMPTOMS)
Return to Section TOC
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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. If OK then the
remote control device may be
faulty. Check or replace.
2. Check for loose or faulty connections in the heavy current carrying
leads (i,e,. output diodes, output
terminals, shunt and main transformer.)
3. Check the input voltages and
input voltage reconnect
procedures. See Installation
Section of this manual.
Poor stick electrode welding
performance. The arc pops out.
Return to Section TOC
F-9
Observe all Safety Guidelines detailed throughout this manual
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F-9
3. Perform Output Diode Test.
4. Perform Control Board Voltage
Test.
1. Check for loose or faulty welding
1. Check for loose or faulty conneccables.
tions in the heavy current carrying
leads (i,e,. output diodes, output
2. Is the electrode DRY? Try weldterminals, shunt and main transing with another electrode from a
former.)
different container. Make sure
you have the correct electrode for
2. Perform Output Diode Test.
the application.
3. Make sure the machine settings
are correct for the weld process
being used.
3. Perform Control Board Voltage
Test.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric
Service Department for technical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.
INVERTEC V250-S
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F-10
NOTES
INVERTEC V250-S
F-10
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
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This test will determine if the auxiliary transformer is functional when the correct primary voltage is applied to the primary winding.
MATERIALS NEEDED
Volt/ohmmeter
Machine wiring diagram
5/16” nut-driver
230VAC isolated power supply
INVERTEC V250-S
F-11
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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
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3. Locate the Auxiliary Transformer just
behind the input line switch on the
lower right side of the machine.
5. Carefully apply the 230VAC isolated
supply to leads H1(1J7) and
H3(2J7) of the auxiliary transformer.
6. Carefully check for the presence of
the following voltages at the appropriate leads. See Table F.1.
AUXILIARY TRANSFOMER
PLUG J7
1J7
2J7
3J7
4J7
5J7
6J7
Figure F.1 Auxiliary Transformer and Plug J7.
INVERTEC V250-S
F-12
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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.
8. If any of the voltages are missing or
very low, with the proper primary
voltage applied, the auxiliary transformer may be faulty. Replace.
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9. If the auxiliary transformer tests good
but does not function when connected to the V250-S check the harness
wiring to the auxiliary transformer.
See wiring diagram.
INVERTEC V250-S
F-13
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F-14
NOTES
INVERTEC V250-S
F-14
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
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This test will help determine if the input rectifier has “shorted” or “open” diodes.
MATERIALS NEEDED
Analog voltmeter/ohmmeter (Multimeter)
Phillips head screwdriver
Wiring diagram
INVERTEC V250-S
F-15
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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.
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3. Locate Input Rectifier (D9) and lead
locations.
#207
#207A
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A
B
C
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#209
Figure F.2 Input Rectifier and Leads.
INVERTEC V250-S
F-16
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F-17
TROUBLESHOOTING & REPAIR
INPUT RECTIFIER TEST (continued)
TABLE F.2 Input Rectifier Test Points
TEST POINT TERMINALS
+ Probe
- Probe
A
B
C
207
207
207
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
A
B
C
209
209
209
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
207
207
207
A
B
C
Less than 100 ohms
Less than 100 ohms
Less than 100 ohms
209
209
209
A
B
C
Greater than 1000 ohms
Greater than 1000 ohms
Greater than 1000 ohms
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6. If the Input Rectifier does not meet
the acceptable readings outlined in
Table F.2. the component may be
faulty. Replace.
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ANALOG METER X10 RANGE
Acceptable Meter Readings
8. If the Input Rectifier is good be sure
to reconnect leads #207, #207A and
#209 to the correct terminals and
torque to 31IN-LBS. See wiring diagram and Figure F.2.
Note: Before replacing the Input
Rectifier(D9) check the input
power switch (S1) and perform
the Power Board Resistance
Test . Also check for leaky or
faulty filter capacitors.
7. When installing a new Input
Rectifier, torque the mounting nuts to
44IN-LBS. A thin coating of Dow
Corning 340 Heat Sink Compound
(Lincoln E1868) is recommended.
Torque the lead terminals to 31INLBS. See Input Rectifier Bridge
Removal And Replacement.
INVERTEC V250-S
F-17
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F-18
NOTES
INVERTEC V250-S
F-18
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if the Power Board has any “shorted” or “leaky” power diodes or
Insulated Gate Bipolar Transistors. Also it will help to indicate any “shorted” filter capacitors.
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MATERIALS NEEDED
Analog voltmeter/ohmmeter (Multimeter)
Wiring diagram
INVERTEC V250-S
F-19
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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.
201
204
+
207A
V250S POWER G2684
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3. Locate the Power Board and associated lead locations. See Figure F.3.
202A
DANGER
HIGH VOLTAGE CAN KILL
209
208
203A
205
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Figure F.3 Power Board Test Points.
INVERTEC V250-S
+
206
F-20
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F-21
TROUBLESHOOTING & REPAIR
POWER BOARD RESISTANCE TEST (continued)
TABLE F.3 Power Board Resistance Test Points.
TEST POINT TERMINALS
+ Probe
- Probe
ANALOG METER X10 RANGE
Acceptable Meter Readings
201
207A
207A
201
Greater than 1000 ohms
Less than 100 ohms
204
207A
207A
204
Greater than 1000 ohms
Less than 100 ohms
202A
204
204
202A
Greater than 1000 ohms
Less than 100 ohms
202A
201
201
202A
Greater than 1000 ohms
Less than 100 ohms
205
203A
203A
205
Greater than 1000 ohms
Less than 100 ohms
208
203A
203A
208
Greater than 1000 ohms
Less than 100 ohms
206
208
208
206
Greater than 1000 ohms
Less than 100 ohms
206
205
205
206
Greater than 1000 ohms
Less than 100 ohms
6. If the power board does not meet the
acceptable readings outlined in
Table F.3. the board may be faulty.
Replace.
See Power Board
Removal and Replacement
Procedure.
Note: Complete power board and filter
capacitor replacement is recommended
.
7. If the power board “passes” the
resistance test proceed to the Power
Board Voltage Test.
Note: Reconnect leads #201, #204,
#205 and #208 to their appropriate terminals.
INVERTEC V250-S
F-21
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F-22
NOTES
INVERTEC V250-S
F-22
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This test will help determine if any of the output diodes are “shorted”.
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MATERIALS NEEDED
Analog voltmeter/ohmmeter (Multimeter)
Wiring diagram. Note: Output diode polarity will vary with machine codes.
INVERTEC V250-S
F-23
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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.
NOTE: THE POLARITY OF THE TEST
LEADS IS MOST IMPORTANT. IF
THE TEST LEADS POLARITY IS NOT
CORRECT THE TEST WILL HAVE
ERRONEOUS RESULTS.
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3. Remove any output cables and load
from the output terminals.
SMAW
SOFT
GTAW
SMAW
CRISP
THERMAL
HOT START
5
4
6
7
3
A
85
120
0
170
50
15
LOCAL
9
1
OUTPUT
REMOTE
8
2
10
ARC FORCE
230
1
5
4
6
7
3
250
8
2
9
1
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0
®
INVERTEC V250-S
-
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+
I
S
O
NEGATIVE
OUTPUT
TERMINAL
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10
POSITIVE
OUTPUT
TERMINAL
Figure F.4 Machine Output Terminals.
INVERTEC V250-S
F-24
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F-25
F-25
TROUBLESHOOTING & REPAIR
OUTPUT DIODES TEST (continued)
®
INVERTEC V250-S
+
-
I
S
E
E
OB
-P
RO
B
PR
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+
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O
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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”.
7. Perform Filter Capacitor Discharge
Procedure detailed in Maintenance
Section.
8. Locate output diodes and snubbers.
See Figure F.6. for machine codes
10102 and 10103 only. See Figure
F.7. for machine codes 10187 and
10188 only.
9. Test all output diodes and snubbers
(if used) individually.
INVERTEC V250-S
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F-26
TROUBLESHOOTING & REPAIR
OUTPUT DIODES TEST (continued)
OUTPUT DIODES
SNUBBERS
Figure F.6 Output Diodes and Snubber Locations (Codes 10102 and 10103)
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DIODE MODULES
Figure F.7 Output Diode Module Locations (Codes 10187 and 10188)
INVERTEC V250-S
F-26
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
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This test will aid the technician in determining if the voltage board or some other machine
component may be faulty.
MATERIALS NEEDED
Voltmeter/ohmmeter (Multimeter)
Wiring diagram.
Power board schematic drawing.
INVERTEC V250-S
F-27
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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. Perform the voltage checks outlined
in Table F.4. making sure all of the
test conditions are in effect.
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3. Locate and familiarize yourself with
the leads and pin locations in plug J6
on the power board. See Figure F.8.
#313 (5J6)
#309 (6J6)
#311 (4J6)
#308 (1J6)
#310 (3J6)
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#307 (2J6)
PLUG J6
207A
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+
20
HIGH VOLTAGE CAN
DANGER
+
2
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203A
Figure F.8 Plug J6 on Power Board
INVERTEC V250-S
201
204
J6
209
208
205
V250S POWER G2684
F-28
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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.
No load on the machine - the
mode switch in SMAW position.
The PWM pulse drive from the
control board to the pulse
transformer primary located on
the power board.
Lead #308 (1J6)
to
Negative output terminal
14VDC.
No load on the machine - the
mode switch in SMAW position.
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
7VDC.
Machine loaded to 250Amps.
The output control R3 at the
maximum position.
The PWM pulse drive from the
control board to the pulse
transformer primary located on
the power board.
Lead #308 (1J6)
to
Negative output terminal
7VDC.
Machine loaded to 250Amps.
The output control R3 at the
maximum position.
CR1 (charge relay) coil voltage.
Lead #309 (6J6)+
to
lead #310 (3J6)
12VDC
This voltage should be present only after the protection
circuit as been satisfied.
This low voltage will be present when the protection circuit has determined that the
filter capacitor voltage is
acceptable. Note: The CR1
charge relay should be activated.
Lead #311 (4J6)+
to
lead #313 (5J6)-
0 to 1VDC.
If voltage protection circuit IS
satisfied.
This voltage will be present
unit the protection circuit
determines that the filter
capacitor is at an acceptable
level.
Note: The CR1 charge relay
will not be activated.
Lead #311 (4J6)+
to
lead #313 (5J6)-
15VDC.
If voltage protection circuit is
NOT satisfied.
INVERTEC V250-S
TEST CONDITIONS
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F-30
NOTES
INVERTEC V250-S
F-30
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
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This test will aid the technician in determining if the control board or some other machine
component may be faulty.
MATERIALS NEEDED
Voltmeter/ohmmeter (Multimeter)
Wiring diagram.
Control board schematic drawing.
INVERTEC V250-S
F-31
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.
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3. Locate and familiarize yourself with
the leads and pin locations in plugs
J1 thru J5 on the control board. See
Figure F.9.
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J1
J2
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. Perform the voltage checks outlined
in Table F.5. making sure all of the
test conditions are in effect.
7J3
(#303)
1J3
(#375)
1J5
(#322)
1J1
(RED LEAD)
3J1
(RED LEAD)
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F-32
TROUBLESHOOTING & REPAIR
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F-32
J5
4J5
(#318)
1J4
(BLACK LEAD)
J3
J4
G2666-[ ]
V250S CONTROL
Figure F.9 Plugs J1-J5 on Control Board
INVERTEC V250-S
2J4
(WHITE LEAD)
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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.
(#2 and #4)
Lead #318 (4J5)
to
Lead #322 (1J5)
0 VDC.
When remote trigger circuit
is “closed”.
Remote trigger circuit test.
(#2 and #4)
Lead #318 (4J5)
to
Lead #322 (1J5)
12VDC.
When remote trigger circuit
is “open”.
Shunt feedback milli-volt
check.
White lead (2J4)+
to
Black lead (1J4)-
100 mV.
Machine loaded to 120
Amps
Check for 15VDC control
board supply voltage.
Lead #303 (7J3)+
to
Lead #375 (1J3)-
15VDC.
The correct input voltage
applied to the V250-S and
the input power switch (S1)
in the ON position.
TEST CONDITIONS
18VAC
The correct input voltage
Note: voltage will vary with applied to the V250-S and
input line voltage.
the input power switch (S1)
in the ON position.
INVERTEC V250-S
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F-34
NOTES
INVERTEC V250-S
F-34
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
This check will aid the technician in the understanding and evaluation of the V250-S protection circuit.
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MATERIALS NEEDED
Voltmeter/ohmmeter (Multimeter)
Machine wiring diagram
Protection circuit simplified wiring diagram
INVERTEC V250-S
F-35
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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.
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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.
6J2
J1
J2
J5
J3
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2J2
G2666-[ ]
Figure F.10 Control Board Plug J2 Test Points
#313 (5J6)
#309 (6J6)
#311 (4J6)
#308 (1J6)
#310 (3J6)
#307 (2J6)
PLUG J6
201
V250S POWER G2684
204
J6
209
208
205
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J4
1J2
V250S CONTROL
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F-36
TROUBLESHOOTING & REPAIR
Figure F.11 Power Board Plug J6 Test Points
INVERTEC V250-S
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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.
If the correct voltage is present at the
control board but not at the power
board check the associated leads
and connections.
If 15VDC is present the overvoltage
protection circuit has not been satisfied. Perform the Capacitor Balance
Test . If the capacitor balance is
good and the overvoltage protection
circuit has NOT been satisfied the
power board may be faulty. Replace.
If the correct voltage, 15VDC, is not
present at the control board the control board may be faulty. Perform the
Control Board Voltage Test.
9. If 15VDC IS present at leads
#309(6J6)+ to #310(3J6)- at the
power board the input relay
(1CR), should activate (pull-in) and
apply full input power to the filter
capacitors.
If this does not take place the power
board may be faulty. Replace.
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If the correct voltage is present at
the power board but not at the control
board check associated leads and
connections.
8. Check for 15VDC at leads
#309(1J2)+ to #310(6J2)- at the control board. If the correct voltage is
present check for 15VDC at leads
#309(6J6) + to #310(3J6)- at the
power board.
7. Check for 0 to 1VDC at leads
#311(2J2)+ to #313(8J2)- at the control board. If the correct voltage is
present go to step 8.
PROTECTION CIRCUIT (SIMPLIFIED)
POWER BOARD
CONTROL BOARD
TIMER
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(4J6)
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F-37
TROUBLESHOOTING & REPAIR
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F-37
O
V
E
R
V
O
L
T
A
G
E
D
E
T
E
C
T
I
O
N
(5J6)
#311
#313
+15VDC
(2J2)
(8J2)
+15VDC
(6J6)
(3J6)
#309
#310
1CR
CHARGE
RELAY
INVERTEC V250-S
(1J2)
(6J2)
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F-38
NOTES
INVERTEC V250-S
F-38
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
TEST DESCRIPTION
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This test will help the technician to determine if the input filter capacitors are being charged
equally and to the correct voltage levels. Note: This test should only be conducted with the
V250-S reconnect switch and “A” jumper configured for 380VAC and above.
MATERIALS NEEDED
Voltmeter/ohmmeter (Multimeter)
Machine wiring diagram.
INVERTEC V250-S
F-39
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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. Put the mode switch S2 in the
SMAW (soft) position and put the
Local/Remote switch S3 in the
LOCAL position.
7. Apply the correct input power† and
turn ON the V250-S.
4. Put the Output Control R3 at the
minimum position.
† Note: This test should only be conducted
with the V250-S reconnect switch and “A”
jumper configured for 380VAC and above.
5. Locate and familiarize yourself with
the capacitor test locations on the
power board. See Figure F.12.
CAPACITOR (C2) TERMINALS
+
207A
V250S POWER G2684
204
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201
202A
DANGER
HIGH VOLTAGE CAN KILL
209
208
203A
+
206
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205
CAPACITOR (C1) TERMINALS
Figure F.12 Power Board and Capacitor Test Locations
INVERTEC V250-S
F-40
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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.
In the event the capacitor voltage is
too high or not balanced (within
20VDC) the protection circuit will prevent output. The overvoltage trip setting is nominal line voltage (230/460)
+15%. Reset occurs about 3% lower
(230/460) +12%.
The capacitors or other components
on the power board may be faulty.
Replace power board.
TABLE F.6 Capacitor Voltages
INPUT APPLIED
EXPECTED VOLTS
DC AT CAPACITOR
TERMINALS
460VAC
440VAC
415VAC
380VAC
325VDC
311VDC
293VDC
269VDC
NOTE
The following machine parts must be replaced in matched sets If
Capacitor C1 is found to be defective, both Capacitors C1 and C2
must be replaced at the same time:
INVERTEC V250-S
F-41
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F-42
NOTES
INVERTEC V250-S
F-42
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
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Small needle-nose pliers
Small screwdriver
5/16” nut-driver
INVERTEC V250-S
F-43
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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. Perform Filter Capacitor Discharge
Procedure detailed in Maintenance
Section.
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3. Locate the control board and the five
molex type plugs that are connected
to it. See Figure F.13.
4. Carefully remove the five molex type
plugs by depressing the locking tabs
and gently extracting the plugs from
the P.C. board receptacles.
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7. Replace the five molex type plugs in
their appropriate receptacles.
5. Using the needle nose-pliers and
small screwdriver gently remove the
control board from the six mounting
pins by depressing the tabs on the
mounting pins and sliding the board
from the pins. See Figure F.13.
J1
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Note: Be sure to observe static electricity precautions when handling
P.C. boards.
J2
8. Inspect, clear and secure all leads in
preparation for case wrap-around
reassembly.
9. Using the 5/16” nut-driver replace
the case wrap-around.
J5
J3
SIX MOUNTING TABS
J4
G2666-[ ]
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V250S CONTROL
DEPRESS LOCKING TAB
ON MOUNTING PIN
Figure F.13 Control Board Plugs and Mounting Pins
INVERTEC V250-S
F-44
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
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5/16” nut-driver
1/4” nut-driver
7/16” wrench
3/16” Allen type wrench
INVERTEC V250-S
F-45
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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. Locate the power board, the molex
type plug J6, the five leads with
push-on connectors and the four
capacitor leads that are connected to
the power board.
Remove leads #202A, #207A,
#203A and #206 from the capacitor
terminals.
PROCEDURE
See Figure F.14. Cut any necessary cable ties.
4. Carefully remove leads (with pushon connectors) #201, #204, #205,
#208, and #209 from the power
board.
201
+
207A
V250S POWER G2684
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204
202A
4 SOCKET HEAD
CAP SCREWS
DANGER
HIGH VOLTAGE CAN KILL
J6
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209
208
203A
+
206
205
Figure F.14 Power Board Lead Locations
INVERTEC V250-S
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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. Carefully remove the power board
taking note as to the amount of heat
sink compound used between the
IGBTs and the large aluminum heat
sink. Note: Be sure to observe static
electricity precautions when handling
P.C. boards.
If the filter capacitors are to be
removed see Filter Capacitor
Removal and Replacement.
13. Assemble the leads #202A, #207A,
#203A and #206 to their respective
capacitor terminals using the bolts,
lockwashers and 7/16” wrench.
Torque to 50 - 60 IN. Lbs.
14. Using the 1/4” nut-driver install the
two screws holding the P.C. board
to the heat sink mounting bracket.
15. Connect leads #201, #204, #205,
#208, and #209 to their appropriate
terminals.
16. Replace plug J6 into power board.
17. Replace any previously removed
cable ties.
18 Inspect, clear and secure all leads
in preparation for case wrap-around
reassembly.
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POWER BOARD REPLACEMENT
PROCEDURE
10. Apply a thin coat of Dow Corning
340 heat sink compound (Lincoln
E1868) to the filter capacitor terminals. Do not apply to screw threads
or threaded area of terminals.
11. When replacing the power board
apply a thin coating (.005 to .010)
of Dow Corning 340 heat sink
compound (Lincoln E1868) to the
mating surfaces between the
IGBTs and the aluminum heat
sink. Compound is NOT permitted
on the screw heads or mounting
hole threads. The mating surfaces
must be clean and free of any foreign material.
12. Install the power board and tighten
the four cap head screws. Torque
the cap head screws to 40 to 48 IN.
Lbs. Note: Before tightening make
certain the capacitor terminals are
aligned with their respective holes
in the power P.C. board.
INVERTEC V250-S
F-47
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F-48
NOTES
INVERTEC V250-S
F-48
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
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5/16” nut-driver
Slot head screwdriver
MATCHED PARTS
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The following machine parts must be replaced in matched sets If Capacitor C1 is found to be
defective, both Capacitors C1 and C2 must be replaced at the same time:
INVERTEC V250-S
F-49
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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.
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F-50
TROUBLESHOOTING & REPAIR
5. Using the 5/16” nut-driver remove
the two screws from the top front of
the case front panel. See Figure
F.15.
6. Using the slot head screwdriver
carefully
disengage
the
heatsink/power board mounting
bracket from the top center panel.
This can be accomplished by sliding
the bracket assembly towards the
rear of the machine while at the
some time gently lifting up on the top
center panel. See Figure F.15.
TOP CENTER PANEL
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MOUNTING BRACKETS
REMOVE
CASE BACK
SCREWS
REMOVE
CASE FRONT
SCREWS
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POWER BOARD
Figure F.15 Heatsink/Power Board Removal
INVERTEC V250-S
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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.
The locking tab on the bottom of the
bracket will have to be lifted slightly
to enable the assembly to slide
freely towards the front.
11. Install the heatsink/power board
bracket assembly (with new capacitors
installed)
into
the
machine by first positioning the
bottom of the bracket into the slots
in the case bottom and sliding the
bracket assembly towards the rear
of the machine.
8. With the bracket assembly out of the
machine the filter capacitors can be
removed by loosening the capacitor
clamps and sliding the filter capacitors out of the assembly.
12. Carefully position the top of the
heatsink/power board bracket
assembly into the top center panel
and slide the panel towards the
rear of the machine while holding
the heatsink/power board mounting
bracket in place.
Note: Before removing the capacitors precisely mark where the capacitors are positioned in the clamp.
This is important so the new capacitor terminals will align with the holes
in the power board. Also mark
polarity
configuration
for
reassembly purposes.
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9. Install the new capacitors taking note
of position in the clamp and also
polarity location.
13. Using the 5/16’ nut-driver replace
the two screws at the top rear of
the case back. See Figure F.15.
14. Using the 5/16” nut-driver replace
the two screws at the top front of
the case front panel. See Figure
F.15.
15. Perform
Power
Board
Replacement Procedure in this
section.
10. Using the slot head screwdriver
tighten the clamps.
INVERTEC V250-S
F-51
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F-52
NOTES
INVERTEC V250-S
F-52
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
Return to Section TOC
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3/16” Allen type wrench
Phillips head screwdriver
7/16” Box wrench
Torque wrench
INVERTEC V250-S
F-53
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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.
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3. Locate the input rectifier and the
leads connected to it. See Figure
F.16.
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F-54
6. Using the 3/16” Allen wrench and
7/16” box wrench remove the two
cap head screws, washers and nuts
mounting the input rectifier bridge to
the center panel assembly.
4. Identify and mark the leads connected to the rectifier terminals.
CAP HEAD
MOUNTING
SCREWS
#207
#207A
A
B
C
#209
Figure F.16 Input Rectifier Lead Locations
INVERTEC V250-S
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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.
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9. Reconnect the eight leads to the correct terminals and torque the phillips
head screws to 31 IN-LBS.
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F-55
INVERTEC V250-S
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F-56
NOTES
INVERTEC V250-S
F-56
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
Return to Section TOC
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MATERIALS NEEDED
Slot head screwdriver
5/16” nut-driver
7/16” wrench
Wire cutters
3/8” wrench
INVERTEC V250-S
F-57
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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. Locate output diode assembly and
associated leads. See Figure F.17.
8. Using the 7/16” wrench remove the
bolt and washers connecting the output cable to the diode heat sink. Be
sure to take note of the small resistor
connection at the same point. See
Figure F.17.
PROCEDURE
4. Cut the necessary wire ties and slide
the sleeving from the four wire connections to be disassembled. See
Figure F.17
5. Label the leads for identification purposes for reassembly.
9. With the 5/16” nut-driver remove the
two screws from the top rear case
back. See Figure F.15.
SNUBBER RESISTORS
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7/16 BOLT
SLEEVED SPLICES
Figure F.17 Output Diode Assembly and Leads
INVERTEC V250-S
F-58
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F-59
TROUBLESHOOTING & REPAIR
OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT
(MACHINE CODES BELOW 10150)
(continued)
LOCKING TABS
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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. This can be accomplished
by lifting the locking tab and sliding
the heat sink assembly towards the
rear of the machine. See Figure
F.18.
11. Carefully remove the output diode
assembly from the V250-S.
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12. Remove the two heat sink holders
from the heat sink/diode assembly.
13. Assemble the two heat sink holders
to the new heat sink/diode assembly.
15. Install the two screws into the top
rear case back. See Figure F.15.
16 Using the 7/16” wrench, bolt and
washers connect the output cable to
the diode heat sink. Be sure to take
note of the small resistor connection
at the same point. See Figure
F.17.
17. Using the 7/16” wrench, bolts, nuts
and washers assemble and tighten
the two splices.
18. Using the 3/8” wrench and slot
head screwdriver assemble and
tighten the other two splices.
19. Position sleeving and secure with
cable ties. Clear all leads and prepare unit for reassembly of wraparound case.
14. Install the new output diode assembly into position and slide it towards
the front of the machine until the
locking tabs (both top and bottom)
are engaged. See Figure F.18.
INVERTEC V250-S
F-59
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F-60
NOTES
INVERTEC V250-S
F-60
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Return to Section TOC
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
MATERIALS NEEDED
Return to Section TOC
Return to Master TOC
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7/16” wrench
1/8” Allen type wrench
Torque wrench
INVERTEC V250-S
F-61
Return to Master TOC
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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.
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3. Locate output diode assembly and
associated leads. See Figure F.19.
4. Label the leads for identification purposes for reassembly.
Return to Section TOC
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7/16 MOUNTING BOLTS
DIODE MODULES
7/16 BOLTED CONNECTIONS
Figure F.19 Output Diode Assembly and Leads
INVERTEC V250-S
F-62
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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. Using 1/8” Allen wrench remove the
center socket head cap screw from
the diode module to be replaced.
14. Tighten the top and bottom screws
to between 5.0 and 10.0 IN-LBS.
8. Carefully remove the diode module.
15. Tighten the center cap screw to
between 12 and 18 IN-LBS.
9. To install the new module first make
sure the heat sink surface is clean
and free of dirt.
16. Further tighten the top and bottom
screws to between 30 and 40
IN-LBS.
10. Apply a thin even coating (.004 to
.010 IN.) of thermal compound
Penetrox A13 (Lincoln E2529) to
the bottom surface of the base
plate. Keep the compound away
from the mounting hole areas.
17. Connect the leads to the proper terminals and tighten the screws to
between 30 to 40 IN-LBS. Do not
stress the module terminals when
making these connections.
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11. Apply a small amount of Loctite
#271 (Lincoln E1777-1) to the first
three threads of the socket head
cap screw.
18. Clear all leads and prepare unit for
reassembly of wrap-around case.
12. Start threading the top and bottom
screws and associated washers by
hand. Also start the center socket
head cap screw and associated
washer.
INVERTEC V250-S
F-63
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F-64
NOTES
INVERTEC V250-S
F-64
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
Return to Section TOC
Return to Master TOC
Return to Section TOC
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MATERIALS NEEDED
7/16” Wrench
3/8” Wrench
Wire cutters
3/4” Wrench
Slot head screwdriver
INVERTEC V250-S
F-65
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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.
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3. Locate main transformer and associated primary leads. See Figure F.20.
5. Locate main transformer and associated secondary leads, reactor leads,
and shunt connections. See Figure
F.21.
4. Disconnect transformer primary
leads #201, #204, #205 and #208
from the power board.
Note: Leads #204 and #205 will
have to be removed from the T3 current transformer. Cut any necessary
201
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204
208
205
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T3 CURRENT TRANSFORMER
MAIN TRANSFORMER
Figure F.20 Main Transformer Right Side
INVERTEC V250-S
F-66
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F-67
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
(MACHINE CODES BELOW 10150)
(continued)
MAIN TRANSFORMER
SECONDARY LEADS
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Figure F.21 Main Transformer Left Side
6. Disconnect and clear the shunt
sensing leads from the control board
(plug J4).
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. Take note of the bypass connection on the negative terminal. Clear the shunt to allow
access to the main transformer and
lead connections. Cut any necessary cable ties.
9. With the 3/4” wrench remove the two
secondary leads from the positive
output terminal. Take note of the bypass connection on the positive terminal.
10. Locate and cut the necessary wire
ties and slide the sleeving from the
four transformer secondary and
reactor lead splices.
11. With slot head screwdriver and 3/8”
nut-driver remove the two reactor
leads from output rectifier leads.
Label the leads for reassembly.
12. Using the 7/16” wrench remove the
secondary leads from the output
rectifier leads.
Label the leads and note washer
and lead placement for reassembly.
13. With 3/8” wrench remove the two
screws mounting the transformer
assembly to the base of the
machine. See Figure F.22. Note:
The machine will have to be tilted
on its side to gain access to the
bottom of the unit.
INVERTEC V250-S
F-67
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F-68
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
(MACHINE CODES BELOW 10150)
(continued)
MAIN TRANSFORMER
LOCKING MOUNTING TABS
MAIN TRANSFORMER
MOUNTING SCREWS
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Figure F.22 Main Transformer Mountings
14. Using the slot head screwdriver
unclip the locking tabs and slide the
transformer towards the front of the
machine until it is free of the slots in
the bottom of the machine.
Note: The machine will have to be
tilted on its side to gain access to
the bottom of the unit.
15. With the main transformer loose
from the base carefully tilt and
remove the transformer from the
left side of the machine.
16. Install the new transformer by tilting
and carefully positioning it in place
in the slots in the case bottom.
Slide towards the rear of the
machine until the locking tabs are
in place.
Note: The machine will have to be
tilted on its side to gain access to
the bottom of the unit.
18. Using the 7/16” wrench reassemble
the two secondary leads to the output rectifier leads. Note lead and
washer placement and lead labels.
19. Using the slot head screwdriver
and 3/8” nut-driver reassemble the
two reactor leads to the output rectifier leads. Note lead labels.
20. Replace the sleeving on the four
connections and replace the cable
ties.
21. With the 3/4” wrench assemble the
two secondary leads to the positive
output terminal.
17. With the 3/8” wrench replace the
two transformer mounting screws.
INVERTEC V250-S
Take note of the by-pass connection on the positive output terminal.
F-68
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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.
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24. Connect the shunt sensing leads to
the control board (plug J4).
25. Connect primary leads #201, #204,
#205 and #208 to the power board.
Be sure leads #204 and #205 are
routed through the current transformer (T3) in the correct manner. Secure leads with cable ties.
26. Clear all leads and secure for case
wrap-around assembly.
INVERTEC V250-S
F-69
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F-70
NOTES
INVERTEC V250-S
F-70
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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. For
your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform
the tests/repairs safely, contact the Lincoln Electric service department for technical
troubleshooting assistance before you proceed.
Call (216) 383-2531 or (800) 833-9353 (WELD).
_____________________________________________________________
Return to Section TOC
Return to Master TOC
Return to Section TOC
Return to Master TOC
MATERIALS NEEDED
7/16” Wrench
3/8” Wrench
Wire cutters
3/4” Wrench
Slot head screwdriver
INVERTEC V250-S
F-71
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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.
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2. Perform Filter Capacitor Discharge
Procedure detailed in Maintenance
Section.
3. Locate main transformer and associated primary leads. See Figure
F.23.
5. Locate main transformer and associated secondary leads, reactor leads,
and shunt connections. See Figure
F.24.
4. Disconnect transformer primary
leads #201, #204, #205 and #208
from the power board.
6. Disconnect and clear the shunt
sensing leads from the control board
(plug J4).
NOTE: Leads #204 and #205 will
have to be removed from the T3 cur-
201
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204
208
205
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T3 CURRENT TRANSFORMER
MAIN TRANSFORMER
Figure F.23 Main Transformer Right Side
INVERTEC V250-S
F-72
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F-73
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
(MACHINE CODES ABOVE 10150)
(continued)
MAIN TRANSFORMER
SECONDARY LEADS
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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. Take note of the bypass connection on the negative terminal. Clear the shunt to allow
access to the main transformer and
lead connections. Cut any necessary cable ties.
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9. With the 3/4” wrench remove the
positive output lead from the positive
output terminal. Take note of the bypass connection on the positive terminal.
10. Locate and cut the necessary wire
ties and slide the sleeving from the
two transformer reactor lead
splices.
11. With slot head screwdriver and 3/8”
nut-driver remove the two reactor
leads from output the rectifier
leads.
Label the leads for
reassembly.
12. Using the 7/16” wrench remove the
four secondary leads from the output rectifier module. Label the leads
and note washer and lead placement for reassembly. See Figure
F.24.
13. With 3/8” wrench remove the two
screws mounting the transformer
assembly to the base of the
machine. See Figure F.25. Note:
The machine will have to be tilted
on its side to gain access to the
bottom of the unit.
INVERTEC V250-S
F-73
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F-74
TROUBLESHOOTING & REPAIR
MAIN TRANSFORMER REMOVAL AND REPLACEMENT
(MACHINE CODES ABOVE 10150)
(continued)
MAIN TRANSFORMER
LOCKING MOUNTING TABS
MAIN TRANSFORMER
MOUNTING SCREWS
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Figure F.25 Main Transformer Mountings
14. Using the slot head screwdriver
unclip the locking tabs and slide the
transformer towards the front of the
machine until it is free of the slots in
the bottom of the machine. Note:
The machine will have to be tilted
on its side to gain access to the
bottom of the unit.
15. With the main transformer loose
from the base carefully tilt and
remove the transformer from the
left side of the machine.
16. Install the new transformer by tilting
and carefully positioning it in place
in the slots in the case bottom.
Slide towards the rear of the
machine until the locking tabs are
in place.
18. Using the 7/16” wrench reassemble
the four secondary leads to the output rectifier module. Note lead and
washer placement and lead labels.
Tighten to between 30 and 40 INLBS.
Do not stress the module terminals
when making these connections.
19. Using the slot head screwdriver
and 3/8” nut-driver reassemble the
two reactor leads to the output rectifier leads. Note lead labels.
20. Replace the sleeving on the reactor
connections and replace the cable
ties.
17. With the 3/8” wrench replace the
two transformer mounting screws.
Note: The machine will have to be
tilted on its side to gain access to
the bottom of the unit.
INVERTEC V250-S
F-74
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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.
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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. Clear leads
and install any necessary cable
ties.
23. Connect the two thermostat leads.
24. Connect the shunt sensing leads to
the control board (plug J4).
25. Connect primary leads #201, #204,
#205 and #208 to the power board.
Be sure leads #204 and #205 are
routed through the current transformer (T3) in the correct manner.
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Secure leads with cable ties.
26. Clear all leads and secure for case
wrap-around assembly.
INVERTEC V250-S
F-75
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F-76
NOTES
INVERTEC V250-S
F-76
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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.
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INPUT IDLE AMPS AND IDLE WATTS
INPUT CURRENT @ IDLE
LESS THAN 2 AMPS
INPUT POWER @ IDLE
LESS THAN 200 WATTS
MAXIMUM ACCEPTABLE OUTPUT (AT MINIMUM OUTPUT SETTINGS)
MODE
AMPS
VOLTS
All
1 Amp
10 VDC.
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MODE
AMPS
VOLTS
All
250 Amps
33 VDC.
OPEN CIRCUIT VOLTAGE RANGE
MODE
VOLTS
All
65 - 80 VDC.
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MINIMUM ACCEPTABLE OUTPUT (AT MAXIMUM OUTPUT SETTINGS)
INVERTEC V250-S
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5
Control PC Board (G2666) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-6
Power PC Board (G2684) Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7
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G-1
INVERTEC V250-S
G-1
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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
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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
.001/400
F
10
R1
2W
F
S
1
C3
D1
L1 LEFT
309
1
310
6
307
7
308
4
311
313
2
8
Y
3
Y
5
T1
MAIN
316
2
317
R
4
317
H2
200208V
1
4
H3
2
H4
3
H5
6
415V
440460V
1
B
J3
J1
377
3
324
4
376
5
330
6
321
7
8
303
305
9
304
10
327
11
12
229
CONTROL
13
319
BOARD
14
1
4 2 5
SWITCH
305
3
303A
CC CRISP
S3
REMOTE
330
LOCAL/REMOTE
LOCAL
SWITCH
CW (MAX)
377
376
R3
OUTPUT
10K
CONTROL
2W
375
375B
CW (MAX)
327
328
6
MODE
CC GTAW
375
2
328
J5
303
303A
CC SOFT
S2
1
R4
ARC FORCE
10K
/INDUCTANCE
2W
CONTROL
3
R6
H1
324
100
R
H2
R
5W
R
322 318
R
H3
CW (MAX)
75 76 77
R5
STRIKE ENERGY
50K
CONTROL
2W
375B
18V
R
230V
380-
W
R
H3
220-
N.C.
3
1
2
1
J2
TRANSFORMER
H3
A
J4
315
J7
2
304
AUX.
F
- ARC
316
FRONT
OUTSIDE
MOTORS
H1
C6
B W
315
FAN
H1
5
H4
H5
T2
AUXILIARY
J4
J1
J5, J6, J7
J2
J3
+
321
TRANSFORMER
THERMAL
OVERLOAD
Y
INDICATOR
NOTES:
N.A.
1. FOR MACHINES SUPPLIED WITH INPUT CABLE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
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.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
Return to Master TOC
TP6
R
A
Return to Master TOC
208
INPUT
G
0.6 AMP
SLOW
BLOW
Return to Section TOC
207A
229
F
INSIDE
C5
TP5
BACK
F
+ ARC
.001/400
AUX.
F
TRANSFORMER
-
207A
+
W
1600/450
ON
-
Return to Section TOC
POWER
OFF
202A
C2
FRONT
201
T3
CURRENT
+
202A
205
201
S
BACK
S
R5
PRIMARY
204
204
2W
R3
206
C1
C4
R2
10
F
R4
N.C.
206
F
BACK
206
D8
F
S
S4
Return to Section TOC
G-2
ELECTRICAL DIAGRAMS
+
Return to Master TOC
Return to Section TOC
G-2
319
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
322
D
318
E
75
C
76
77
B
A
G
F
MIN
75
76
77
2
GTAW (REMOTE)
4
TRIGGER
REMOTE
OUTPUT
CONTROL
GND
REMOTE
CONTROL
RECEPTACLE
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.D. D2 THRU D4 OUTPUT DIODES ARE A MATCHED SET.
D5 THRU D7 OUTPUT DIODES ARE A MATCHED SET.
N.E. C1, C2 CAPACITORS ARE A MATCHED SET.
ELECTRICAL SYMBOLS PER E1537
CLEVELAND, OHIO U.S.A.
8-5-94
L9280
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
INVERTEC V250S
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.
F
F
S
1
308
2
307
3
310
4
311
5
313
6
309
10
F
2W
D1B
L1 LEFT
309
1
310
6
307
7
308
4
311
313
8
Y
3
Y
5
316
2
317
R
4
320
T1
OUTPUT
MAIN
2
J4
RECTIFIER
TRANSFORMER
HEATSINK
318
R
3
1
FAN
J3
J1
CONTROL
316
BOARD
2
W
1
B
2
377
3
324
4
376
5
330
6
321
7
8
303
305
9
304
10
327
11
328
12
229
13
319
14
J5
J7
H2
200208V
1
4
H3
2
H4
3
H5
6
415V
A
N.C.
440460V
305
3
303A
H3
S3
REMOTE
330
LOCAL/REMOTE
LOCAL
SWITCH
CW (MAX)
377
376
R3
OUTPUT
10K
CONTROL
2W
375
375B
327
CW (MAX)
324
H2
CC CRISP
R4
ARC FORCE
10K
/INDUCTANCE
2W
CONTROL
3
H1
322 318
MODE
CW (MAX)
75 76 77
R5
STRIKE ENERGY
50K
CONTROL
2W
375B
18V
R
230V
380-
6
R
H3
220-
4 2 5
CC GTAW
SWITCH
328
H3
1
303
303A
CC SOFT
S2
1
375
1
J2
HEATSINK
MOTORS
H1
2
304
D2A
S
INSIDE
208
320
FRONT
OUTSIDE
BACK
- ARC
B W
317
POWER BOARD
A
C6
SHUNT
F
FRONT
318
H1
Return to Master TOC
TRANSFORMER
207A
BRIDGE
A
5
H4
H5
T2
AUXILIARY
J4
J1
J5, J6, J7
J2
J3
+
321
TRANSFORMER
THERMAL
OVERLOAD
Y
INDICATOR
NOTES:
N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
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.
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
Return to Master TOC
S
F
229
D2B
BACK
205
Y
T3
CURRENT
INPUT
G
0.6 AMP
SLOW
BLOW
Return to Section TOC
1600/450
207A
+
R
INPUT
PER
N.A.
H1
H1
TP1
F
INSIDE
201
205
205
202A
C2
ON
-
Return to Section TOC
POWER
U
F
F
+
202A
W
S
203
202A
OFF
FRONT
C5
TP5
R5
PRIMARY
204
204
AUX.
R3
206
C1
2W
BACK
S
+ ARC
10
F
R4
N.C.
206
F
BACK
D1A
F
S
S4
Return to Section TOC
G-3
ELECTRICAL DIAGRAMS
+
Return to Master TOC
Return to Section TOC
G-3
319
CONNECTOR CAVITY NUMBERING SEQUENCE
(VIEWED FROM COMPONENT SIDE OF BOARD)
COLOR CODE:
B = BLACK
G = GREEN
R = RED
W = WHITE
Y = YELLOW
322
D
2
GTAW (REMOTE)
318
E
4
TRIGGER
75
C
76
77
B
A
G
F
MIN
75
76
77
REMOTE
OUTPUT
CONTROL
GND
REMOTE
CONTROL
RECEPTACLE
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 440-460V OPERATION.
N.D. D2 THRU D4 OUTPUT DIODES ARE A MATCHED SET.
D5 THRU D7 OUTPUT DIODES ARE A MATCHED SET.
N.E. C1, C2 CAPACITORS ARE A MATCHED SET.
ELECTRICAL SYMBOLS PER E1537
CLEVELAND, OHIO U.S.A.
9-29-95E
L9907
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
INVERTEC V250S
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. BOARD AS'BLY
G2666
R88
Return to Master TOC
Return to Section TOC
G-4
C33
R69
R55
R68
R56
R53
R108
R66
R65
R67
D44
R52
R81
C32
C26
DZ9
D23
R51
D32
Q4
DZ8
D5
D22
R3
D45
R49
R48
D46
R37
R36
C21
DZ12
R38
C13
C12
R41
R21
C19
R20
R19
C18
C17
C14
C16
C45
R18
X5
DZ4
DZ2
R1
C3
D3
D2
V250S CONTROL
C4
C2
J1
X1
C9
C8
R14
R7
C5
X2
D1
R11
D6
C6
R16
C7
D7
D4
R10
R12
R8
D29
DZ3
X3
C10
R9
J2
C20
R13
R15
DZ5
C11
X4
Q1
D8
TP1
R17
C15
DZ7
R24
R25
R27
R26
R44
R29
R28
R23
DZ1
R4
D9
C49
R6
R35
Q2
R128
D10
C24
Q7
R130
D12
D13
D11
R33
D14
R2
C1
R22
C23
C22
R42
R46
R107
Return to Master TOC
R47
C25
R40
D19
D18
D21
D17
R60
D16
D15
C35
R106
Return to Master TOC
R87
Q3
R129
R45
D35
Return to Section TOC
R58
R39
R5
Return to Section TOC
D20
R57
D30
C30
R31
Q6
R32
R30
R112
R125
R126
R110
R124
R123
R127
X6
R54
R111
R121
D26
X8
Q5
R122
R120
D24
R115
J5
Return to Master TOC
Return to Section TOC
R113
C27
C31
X7
R78
D31
D42
D39
D28
R62
C29
R61
R114
R82
D27
C40
R119
C28
J3
R70
C39
R59
D38
R80
R79
C38
D37
D43
C36
R77
C46
R93
DZ11
R76
R92
D34
R75
D33
R71
R74
X9
R73
R84
R72
R85
C42
R118
R83
R117
C41
R116
CAPACITORS = MFD/VOLTS
RESISTORS = OHMS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
INVERTEC V250S
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
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. AS'BLY
J6
D7
R78
C10
R61
CR1
OCI2
T1
R50
R51
R59
R58
R60
R57
D4
R72
R10
X2
R74
R56
R40
R35
D2
R12
R15
R26
X1
R71
C7
R11
R13
D5
C3
D3
R52
R53
R55
R73
Return to Section TOC
G-5
ELECTRICAL DIAGRAMS
R14
R27
R39
R34
R36
R18
R75
C6
C9
R16
R31
R77
DZ15
R47
R37
R76
C4
R32
R48
OCI1
R19
R17
DZ4
D9
Q1
D10
B207A
B203A
DZ11
R45
R25
DZ6
R22
R21
DZ14
DZ1
B206
R1
R6
R64
DZ2
R4
R3
R62
R2
DZ12
R30
C1
R5
R67
R8
DZ13
R7
C11
R29
R63
C2
C12
R65
V25OS POWER
DZ7
D8
DZ9
G2684
D11
R23
R46
R66
R69
Return to Master TOC
C5
R24
DZ10
R41
A1
A2
R44
C8
R68
Return to Section TOC
R20
R43
R42
B202A
DZ5
DZ3
CAPACITORS = MFD/VOLTS
Return to Master TOC
Return to Section TOC
RESISTORS = OHMS
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
INVERTEC V250S
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
+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
1.8
10K
2
20V
3
4
6
7
R78
R87
100K
40V
8.25K
3.32K
C25
100
R32
R110
R111
R112
562
562
562
562
562
562
R116
R117
R118
R119
R120
R121
562
562
R31
562
562
562
562
R122
R123
R124
R125
R126
R127
562
562
562
562
562
562
8
22.1K
11
J3
DZ9
6.19K
10
3
4.75K
R61
47.5K
1W
4
D19
D38
SYNC
SG3847
12
R80
1W
10
9
RT
100K
PWM
CONTROL
C14
50V
soft
47.5K
47p
100V
12
X7 C
11
R52
10
332K
2.21K
Vi
OVERCURRENT
FOLDBACK
+15V
D42
J3
4
R114
X7
2
47.5
10K
D26
D40
DZ11
5.1V
1W
1
C28
.022
13
6
1N914
C47
4.7
R85
50V
Vref
100K
J3
1
Vref
R115
47.5
R109
J5
t
R93
R76
LOCAL
J3
1
X6
9
8
1
7
J3
R101
47.5K
3
100K
Vref
X8
R98
1
crisp
3
R59
D44
SD'
600mA
40V
13.7K
10K
+15V
FILENAME: G2665_1CB
10K
D43
SOFT SCRATCH
C50
X8
X6
HEXTRGR
5
C8
.022
.022
LM224
14
4
4
14
+15V
J5
Q5
R64
2
100K
100
50V
C32
X9
.022
LT1014
50V
75
o
C31
4066B
50V
.022
7
R45
J5
11
GENERAL INFORMATION
LAST NO. USED
R-
ELECTRICAL SYMBOLS PER E1537
.022
50V
7
6
X6
C13
M F D ( .022/50V
CAPACITORS =
9
X6
RESISTORS = Ohms (
8
DIODES =
1A, 400V
1/4W
C-
UNLESS OTHERWISE SPECIFIED)
LABELS
UNLESS OTHERWISE SPECIFIED)
(UNLESS OTHERWISE SPECIFIED)
D-
SUPPLY
8
130
Q- 7
51
X- 9
46
DZ- 12
VOLTAGE NET
POWER SUPPLY SOURCE POINT
5
D39
56
X5
4536B
11
5
16
X7
50V
t
D36
35V
332K
Vi
+15V
R86
1.50K
C48
1.0
R103
.022
50V
2
TIG
R99
332K
CURRENT
CONTROL
AMPLIFIER
1W
C38
10K
47.5K
R96
DZ10
5.1V
R43
SPDT-Center off
.022
50V
R79
4.75K
R82
REMOTE
6.19K
R94
33.2K
2
C40
SWITCH
7
X9
5
10K
R102
5
MODE
33.2K
10K
56
100V
6
R92
o
R46
76
150p
332K
3
77
C46
Vi
D41
7
X8
5
35V
R97
OUTPUT
R95
CW
50V
11
C16
crisp
1.00K
6.2V
2
CT
.022
35V
150p
.022
Vref
R81
soft
DZ7
COMP
C39
4.7
13
4.75K
.022
10K
D37
6.81K
OUTA
C9
14
47p
50V
R58
C36
50V
R47
R113
GND
V-
15
50V
82.5K
R73
47.5
V+
+15V
16
.0047
TEST PT E
R74
SD'
Vc
C26
10V
15.0K
1N914
ARC FORCE
50V
OUTB
I+
R75
D33
X6
C29
.022
Vin
I-
50V
X9
3.32K
R62
crisp
SHUT
Vref
.018
8
R70
6
50V
COMMON CONNECTION
6
t
Return to Master TOC
2700p
50V
C11
R77
10
CW
.1
Return to Master TOC
J3
9
X7 D
1.50K
C30
Return to Section TOC
C19
332
9
R53
8
R57
DETECTOR
10K
D27
C45
R71
8.25K
SHORTING
D20
D28
56.2K
X3
CLIM
100V
C15
20V
Vref
J3
7
18.2K
R13
Q6
600mA
R72
75VDC
OCV
D30
R18
R30
12
+ ARC
+15V
R17
R39
1.50K
crisp
J2
1.0A
10K
600mA
100K
J3
50K
D24
E
D7
R19
Vref
Q2
R56
4.7
2.21K
C18
20V
HOLD DOWN
100K
13
STRIKE
J3
30V
TSC4429JJA
R22
D15
5
soft
1.0A
35V
2.21K
26.7
D21
CONTROL
D35
4.7
R33
50V
1/2W
50 V
R69
3
R84
+15V
STARTING
MAX
C7
C22
D18
O.C.V.
10K
D31
STICK
Return to Section TOC
50V
C33
2
R105
47.5K
J3
0.1
5
30V
.022
100V
26.7
FEEDBACK
56.2K
Vref
3
C5
6
GND
D17
J2
5
.15
50V
CW
8
7
OUT
3
-IFB
47.5K
MAX
VS
OUT
1W
FEEDBACK
CURRENT
Vi
CONTROL
X4
J2
50V
TRIGGER
INTERFACE
50V
J3
GND
R14
.1
NC
1N4936
C43
50V
IN
4
50V
12V
J3
VS
2
3
2.67K
C51
0.1
1
26.7K
2.94K
C10
R100
100
R15
R20
R90
TRANSFORMER
12
X6
12
R104
1W
R42
J4
2
R49
56
14
X9
TO PULSE
TSC4429JJA
100K
R55
+
13
R89
30V
C1
R4
1
R88
SHUNT
t
0.1
50V
5
4
1.0A
R3
332K
D14
Vi
GND
J2
D8
C20
D5
R2
10K
J5
TEST PT D
56.2K
J4
X6
75V
1W
100K
500mA
+15V
4
R91
10
50V
50V
C44
crisp
.1
4
SHUNT
AMPLIFIER
11
13
DZ8
D45
D22
1
4536B
2
GND
0.1
DZ4
13
OUT
6
50V
12V
267
47.5
OUT
7
1W
18V
2.67K
8
D23
56
J5
9
100K
50V
NC
4
C6
DZ2
150
X2
R21
.0047
J2
IN 1
+15V
D1
D4
C4
DZ1
R40
3
15
X5
R107
100K
MONO IN
RESET
3
R24
R129
R37
2
o
PROTECTION
CIRCUIT
R36
243
C3
Y
THERMAL
LIGHT
332K
t
332K
V DD
SET
R67
ADJ
50V
15J
(+)
33.2K
J1
16
LM350
3300
50V
IN
3
267
1.50K
VS
VS
2
R7
OUT
F
30V
1
X1
C2
TP1
J1
6
J3
9
R65
10K
R34
1.0A
.24
5W
IN
FROM AUXILIARY
TRANSFORMER
1.50K
8
R38
R44
4
D6
1.0
18VAC
10
50V
1
FROM
4.75K
X8
D10
J2
D2
J1
J1
THERMOSTATS
.1
15.0K
D3
1
R66
2
1W
1W
47.5
D29
+t
R1
33.2K
2
Return to Master TOC
R106
R130
600mA
40V
D46
C12
R9
100K
DZ3
20V
15V
50V
1.00K
RELAY COILS
6
Q1
S
DZ5
D12
Q7
+15V
8
C23
33.2K
.1
+15V
1
J2
G
R23
D11
J2
R26
R128
33.2K
D
R16
600mA
40V
R41
1.00K
10.0
4A
R10
Q3
R28
10.0
221
R12
DZ12
12V
R11
PRECHARGE TIMER
+15V
R51
2665
Return to Master TOC
Control PC Board (G2666) Schematic
1W
Return to Section TOC
G-6
ELECTRICAL DIAGRAMS
G
Return to Section TOC
G-6
R60
56
C35
o
D34
4
X7
FRAME CONNECTION
3
.1
50V
EARTH GROUND CONNECTION
NOTES :
N.A.
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
NUMBER.
UNLESS OTHERWISE SPECIFIED TOLERANCE
Ch'ge.Sht.No.
ON HOLES SIZES PER E-2056
ON 3 PLACE DECIMALS IS + .OO2
SCHEMATIC
SUBJECT
SCALE
ON ALL ANGLES IS + .5 OF A DEGREE
WITH PUBLISHED STANDARDS
V250S CONTROL
TYPE
CLEVELAND, OHIO U.S.A.
ON 2 PLACE DECIMALS IS + .O2
MATERIAL TOLERANCE ("t") TO AGREE
EQUIP.
THE LINCOLN ELECTRIC CO.
DR.
DATE
CHK.
SUP'S'D'G.
SHT.
NO.
G
2665
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
INVERTEC V250S
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.
.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.
CNY17-3V
2
2500
681K
5W
6
(VOLTAGE PROTECTION)
4
APT6035N
S
8
D11
2.7
.022
50V
J6
R69
5
5W
1A
1000V
2.7
5W
1.82K
DZ15
R77
10.0
15V
150K
8
C10
PRIMARY
1000V
A2
R74
D
DZ13
X2
3.32K
D4
201
TRANSFORMER
C12
9
R68
1W
2
9
A
6
A
10
10
1
R58
325VDC
(NOMINAL)
10K
3
150K
A2
R67
332K
6.19K
X2
2500
6.2V
16.5K
RESISTORS
R72
A
C
BYT12P600
10.0
DZ12
R56
2500
A2
R62
R53
BLEEDER
R71
2500
5W
4
PROTECTION
+15V
R59
5
Ch'ge.Sht.No.
OVERVOLTAGE
1000V
7
SCHEMATIC
SUP'S'D'G.
1000V
.0047
EARTH GROUND CONNECTION
CHK.
2.7
5W
1A
R57
DZ11
D10
1
1W
WITH PUBLISHED STANDARDS
DZ10
5W
APT6035N
10.0
R55
DZ9
2.7
R52
(PWM DRIVE)
R48
A2
G
MATERIAL TOLERANCE ("t") TO AGREE
1W
3
R60
R46
R61
6.2V
ON ALL ANGLES IS + .5 OF A DEGREE
D
G4
NOTES :
GATE
7
RECONNECT
2
R50
BOARD
B
R41
S4
R47
CONTROL
202A
10.0
G3
R45
FROM
6
ON HOLES SIZES PER E-2056
S3
GATE
9
ON 2 PLACE DECIMALS IS + .O2
4
12
ON 3 PLACE DECIMALS IS + .OO2
DRIVE
R44
J6
FRAME CONNECTION
COMMON CONNECTION
POWER SUPPLY SOURCE POINT
VOLTAGE NET
SUPPLY
203A
RECONNECT
10 S2
UNLESS OTHERWISE SPECIFIED TOLERANCE
S1
GATE
R43
2
R36
5W
1W
G2
1
16.5K
15V
G1
GATE
1
562
2.7
3
J6
35V
6.19K
NUMBER.
1A
REF
6
5W
1000V
50V
27
NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE
2.7
D3
C7
8
WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY
.0047
-
6
SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE
8
C5
1.00K
TL431
R27
D9
1
X1
R75
S
+
7
X2
2.8K
R39
APT6035N
R26
1.00K
R24
1.00K
R23
R21
DZ7
5
R22
1.00K
1000V
G
10.0
DZ6
.0047
A1
10
R25
1W
8
C6
D
6.2V
T1
208
TRANSFORMER
PRIMARY
9
R76
C
DZ5
DZ-
332K
5
A
10.0
X-
R40
A1
6
11
D2
DR.
325VDC
2500
5W
R37
C
+15V
R30
2500
5W
R34
R29
A
R32
7
2
15
PRIMARY
A1
4
GENERAL INFORMATION
TRANSFORMER
R35
Return to Master TOC
C
5
BYT12P600
1W
Q- 1
267K
205
15V
12
C4
C2
50V
R19
.0047
1W
R20
78
2
NONE
6
8-23-93
4
DATE
1W
SCALE
12V
900V
5W
LC
4A
2.7
R7
1A
1.82K
CNY17-3V
1000V
C1
15V
R18
1
OCI1
DZ4
CLEVELAND, OHIO U.S.A.
Q1
D8
1
1.00K
R5
R3
DZ3
1.00K
R4
1.00K
R2
1.00K
5
100
5W
N.A.
S
15V
1W
2.7
APT6035N
10.0
DZ2
R17
R8
G
EQUIP.
A1
3
R6
SUBJECT
D
150K
THE LINCOLN ELECTRIC CO.
100
10W
3
CAPACITOR
PRECHARGE
(UNLESS OTHERWISE SPECIFIED)
150K
1A, 400V
2
R15
150K
DIODES =
10W
R14
150K
UNLESS OTHERWISE SPECIFIED)
100
R12
10W
J6
R13
UNLESS OTHERWISE SPECIFIED)
100
5
6
R11
1/4W
R10
M F D ( .022/50V
3
CAPACITORS =
D
LABELS
CR1
4
R16
206
1W
Return to Master TOC
D7
1
RECONNECT
6.2V
Return to Master TOC
2
CR1
209
10.0
DZ1
Return to Section TOC
INPUT RECTIFIER
POSITIVE
13
RESISTORS = Ohms (
14
X2
11
R1
Return to Section TOC
LAST NO. USED
6
12
D-
J6
LM224
C-
FROM CONTROL BD.
X2
R-
(RELAY DRIVE)
4
C3
ELECTRICAL SYMBOLS PER E1537
+15V
L9304_1BA
Power PC Board (G2684) Schematic
CR1
Return to Section TOC
G-7
ELECTRICAL DIAGRAMS
R31
Return to Master TOC
Return to Section TOC
G-7
15V
1W
1W
207A
NOTE: 202,203,206,&207 BOLT ON WITH FILTER CAPS
NEGATIVE
INPUT RECTIFIER
NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not
available from Lincoln Electric. This information is provided for reference only. Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result
INVERTEC V250S
in danger to the Machine Operator or Technician. Improper PC board repairs could result in damage to the machine.