Lincoln Electric V250-S - Manual

Lincoln Electric V250-S

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – vi; MASTER TABLE OF CONTENTS FOR ALL SECTIONS; PAGE; RETURN TO MAIN INDEX
  • Page 7 – INSTALLATION; TABLE OF CONTENTS
  • Page 8 – PHYSICAL DIMENSIONS; Hz; INPUT; Technical Specifications - Invertec V250-S
  • Page 9 – SAFETY PRECAUTIONS; • Have an electrician install and ser-; SELECT SUITABLE LOCATION; • The machine must be located where there is free cir-; INPUT CONNECTIONS; Supply line entry provision is in the case rear panel.
  • Page 10 – INPUT FUSE AND SUPPLY WIRE; Technical Specifications page at the; Return to Section TOC; RECONNECT PROCEDURE; CAUTION; Figure A.1 Input Voltage Reconnect Instructions
  • Page 11 – OUTPUT CONNECTIONS; FIGURE A.2 OUTPUT CONNECTIONS; REMOTE CONTROL RECEPTACLE; Cable Sizes for Combined Length of Electrode and; QUICK DISCONNECT PLUGS
  • Page 12 – NOTES
  • Page 13 – OPERATION
  • Page 14 – GENERAL DESCRIPTION; OPERATIONAL FEATURES; SAFETY INSTRUCTIONS; ELECTRIC SHOCK can kill.
  • Page 15 – Power Switch - Place the lever in the “ON” position; CC Crisp; Hot Start - Controls the amount of starting energy; CONTROLS AND SETTINGS
  • Page 16 – CONSTANT CURRENT PROCESSES; AIR CARBON ARC CUTTING
  • Page 17 – PARALLEL OPERATION
  • Page 19 – ACCESSORIES
  • Page 20 – OPTIONS / ACCESSORIES; CABLE PLUGS; K857 - Remote Output Control for stick welding.; for TIG welding. When the; for TIG welding. When the
  • Page 21 – MAINTENANCE
  • Page 22 – ELECTRIC SHOCK; FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
  • Page 23 – ROUTINE MAINTENANCE
  • Page 24 – FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
  • Page 25 – THEORY OF OPERATION
  • Page 26 – INPUT LINE VOLTAGE
  • Page 27 – PRECHARGE AND PROTECTION; IGBT Operation Discussion and diagrams in
  • Page 28 – MAIN TRANSFORMER; FIGURE E.3 MAIN TRANSFORMER
  • Page 29 – IGBT Operation Discussion
  • Page 30 – PROTECTION CIRCUITS; OVERLOAD PROTECTION; Machine did not have power applied for many; THERMAL PROTECTION
  • Page 31 – FIGURE E.6 IGBT OPERATION
  • Page 32 – PULSE WIDTH MODULATION; MINIMUM OUTPUT; conducting for 1 microsecond. The negative; MAXIMUM OUTPUT; FIGURE E.7 TYPICAL IGBT OUTPUTS
  • Page 33 – TROUBLESHOOTING & REPAIR; REPAIR AND REPLACEMENT PROCEDURES
  • Page 34 – HOW TO USE TROUBLESHOOTING GUIDE
  • Page 35 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 36 – Observe all Safety Guidelines detailed throughout this manual; OUTPUT PROBLEMS; The input power switch must be; Auxiliary
  • Page 37 – The mode switch must be in one
  • Page 38 – Input
  • Page 40 – Check the input voltage and input; Input Voltage Reconnect; Check for loose or faulty welding
  • Page 41 – WELDING PROBLEMS; Installation
  • Page 43 – TEST DESCRIPTION
  • Page 44 – TEST PROCEDURE; AUXILIARY TRANSFOMER; Figure F.1 Auxiliary Transformer and Plug J7.
  • Page 45 – TABLE F.1 Auxiliary Transformer Test Points
  • Page 48 – R e m o v e m a i n i n p u t p o w e r t o t h e; Filter Capacitor Discharge; With the Phillips head screwdriver
  • Page 49 – If the Input Rectifier does not meet; TABLE F.2 Input Rectifier Test Points
  • Page 53 – If the power board does not meet the; P o w e r B o a r d; resistance test proceed to the; Power; TEST POINT TERMINALS; TABLE F.3 Power Board Resistance Test Points.
  • Page 56 – R e m o v e m a i n i n p u t p o w e r t o t h e
  • Page 57 – If more than 200 ohms is measured; Test all output diodes and snubbers
  • Page 58 – OUTPUT DIODES; DIODE MODULES
  • Page 60 – PLUG J6; Figure F.8 Plug J6 on Power Board
  • Page 64 – F i l t e r C a p a c i t o r
  • Page 68 – Locate and familiarize yourself with; Control Board Plug J2 Test Points; Power Board Plug J6 Test Points
  • Page 69 – The following tests will be performed; Capacitor Balance; C h e c k f o r 0 t o 1 V D C a t l e a d s; POWER BOARD
  • Page 72 – † Note: This test should only be conducted; Figure F.12 Power Board and Capacitor Test Locations
  • Page 73 – maintenance section.; TABLE F.6 Capacitor Voltages; NOTE
  • Page 75 – MATERIALS NEEDED
  • Page 76 – PROCEDURE; CONTROL BOARD REMOVAL AND REPLACEMENT (continued); SIX MOUNTING TABS; Control Board Plugs and Mounting Pins
  • Page 78 – Remove plug J6 by depressing the; POWER BOARD REMOVAL AND REPLACEMENT (continued); Power Board Lead Locations
  • Page 81 – MATCHED PARTS
  • Page 82 – P e r f o r m; P o w e r B o a r d R e m o v a l; U s i n g t h e s l o t h e a d s c r e w d r i v e r; FILTER CAPACITOR REMOVAL AND REPLACEMENT (continued)
  • Page 83 – With the bracket assembly out of the
  • Page 86 – L o c a t e t h e i n p u t r e c t i f i e r a n d t h e; INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT (continued); Figure F.16 Input Rectifier Lead Locations
  • Page 87 – Carefully remove the input rectifier
  • Page 90 – Locate output diode assembly and; OUTPUT DIODE ASSEMBLY REMOVAL AND REPLACEMENT; SLEEVED SPLICES; Figure F.17 Output Diode Assembly and Leads
  • Page 91 – F i g u r e; LOCKING TABS; Figure F.18 Heatsink Removal
  • Page 94 – Figure F.19 Output Diode Assembly and Leads
  • Page 98 – D i s c o n n e c t t r a n s f o r m e r p r i m a r y; MAIN TRANSFORMER REMOVAL AND REPLACEMENT; T3 CURRENT TRANSFORMER; Figure F.20 Main Transformer Right Side
  • Page 99 – D i s c o n n e c t a n d c l e a r t h e s h u n t; Figure F.21 Main Transformer Left Side
  • Page 100 – Figure F.22 Main Transformer Mountings
  • Page 101 – Reassemble the shunt assembly to
  • Page 104 – Figure; Figure F.23 Main Transformer Right Side
  • Page 105 – D i s c o n n e c t t h e t h e r m o s t a t l e a d s; Figure F.24 Main Transformer Left Side
  • Page 106 – Figure F.25 Main Transformer Mountings; U s i n g t h e s l o t h e a d s c r e w d r i v e r
  • Page 109 – RETEST AFTER REPAIR; INPUT IDLE AMPS AND IDLE WATTS; LESS THAN 2 AMPS
  • Page 111 – ELECTRICAL DIAGRAMS; Return to Master TOC
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INVERTEC V250-S

SERVICE MANUAL

Sales and Service through Subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

World's Leader in Welding and Cutting Products

Premier Manufacturer of Industrial Motors

SVM124-A

July, 1996

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 thought-
f u l o p e r a t i o n o n y o u r p a r t .

D O

N O T I N S T A L L , O P E R A T E O R
R E P A I R T H I S E Q U I P M E N T
W I T H O U T R E A D I N G T H I S
M A N U A L A N D T H E S A F E T Y
P R E C A U T I O N S C O N T A I N E D
T H R O U G H O U T .

A n d , m o s t

importantly, think before you act
and be careful.

For use with machine Code Numbers 10102 to 10188

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

View Safety Info

View Safety Info

View Safety Info

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RETURN TO MAIN INDEX

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Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Opera...

Page 3 - ii

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lenss...

Page 4 - iii

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, al...

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