Lincoln Electric INVERTEC V250-S Service Manual
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Lincoln Electric INVERTEC V250-S Service Manual

Lincoln Electric INVERTEC V250-S Service Manual

Lincoln electric welder user manual
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See also: Operator's Manual
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-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
World's Leader in Welding and Cutting Products
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
RETURN TO MAIN INDEX
INVERTEC V250-S
For use with machine Code Numbers 10102 to 10188
THIS
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
SVM124-A
Premier Manufacturer of Industrial Motors
July, 1996

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Summary of Contents for Lincoln Electric INVERTEC V250-S

  • Page 1 INVERTEC V250-S For use with machine Code Numbers 10102 to 10188 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- ful operation on your part.

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions 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.

  • Page 6: Table Of Contents

    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 RETURN TO MAIN INDEX INVERTEC V250-S PAGE...

  • Page 7: Installation Section

    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 INSTALLATION TABLE OF CONTENTS -INSTALLATION SECTION- INVERTEC V250-S SECTION-A-1...

  • Page 8: Installation

    Technical Specifications - Invertec V250-S THREE PHASE Standard Input Current Voltage at Rated Output 208/230/460 34/32/16 200/220/400/440 35/33/18/17 THREE PHASE Volts at Duty Cycle Amps Rated Amps 35% Duty Cycle 60% Duty Cycle 28-32 100% Duty Cycle 26.5 28 † -30...

  • Page 9: Safety Precautions

    INPUT CONNECTIONS can kill. 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.

  • Page 10: Input Voltage Reconnect Procedure

    3.0 Nm. 3. Install in accordance with all local and national electric codes. 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.

  • Page 11: Output Connections

    6 PIN OUTPUT REMOTE RECEPTACLE REMOTE LOCAL INVERTEC V250-S OUTPUT TERMINALS FIGURE A.2 OUTPUT CONNECTIONS 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.
  • Page 12 NOTES INVERTEC V250-S...

  • Page 13: Operation Section

    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 OPERATION TABLE OF CONTENTS -OPERATION SECTION- INVERTEC V250-S SECTION-B-1...

  • Page 14: Operation

    Observe all safety information throughout this manual. OPERATION 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).

  • Page 15: Controls And Settings

    OUTPUT ARC FORCE REMOTE LOCAL ® INVERTEC V250-S 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.

  • Page 16: Constant Current Processes

    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 elec- trode holder being the only equipment required. AIR CARBON ARC CUTTING Air carbon arc cutting may be performed with the Invertec within its output rating using 5/32"...

  • Page 17: Parallel Operation

    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...
  • Page 18 NOTES INVERTEC V250-S...

  • Page 19: Accessories Section

    SECTION C-1 OPTIONS / 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 ACCESSORIES TABLE OF CONTENTS -ACCESSORIES SECTION- INVERTEC V250-S SECTION C-1...

  • Page 20: Accessories

    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...

  • Page 21: Routine Maintenance

    SECTION D-1 SECTION D-1 MAINTENANCE TABLE OF CONTENTS -MAINTENANCE SECTION- INPUT FILTER CAPACITOR DISCHARGE PROCEDURE...D-2 ROUTINE MAINTENANCE...D-3 FILTER CAPACITOR CONDITIONING ...D-3 LOCATION OF MAINTENANCE COMPONENTS...D-4 INVERTEC V250-S...

  • Page 22: Maintenance

    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. POWER UPPER BOARD CAPACITOR TERMINALS INSULATED GLOVES INVERTEC V250-S LOWER CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS...

  • Page 23: Routine Maintenance

    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. INVERTEC V250-S...

  • Page 24: Location Of Maintenance Components

    MAINTENANCE FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. INPUT RECTIFIER CONTROL PC BOARD POWER PC BOARD POWER SWITCH COOLING FANS OUTPUT TERMINALS OUTPUT RECTIFIER HEATSINK FINS MAIN TRANSFORMER AUXILIARY TRANSFORMER INVERTEC V250-S...

  • Page 25: Theory Of Operation Section

    THEORY OF OPERATION TABLE OF CONTENTS -THEORY OF OPERATION SECTION- 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 INVERTEC V250-S...

  • Page 26: Theory Of Operation

    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.

  • Page 27: Precharge And Protection

    RELAY IGBT CAPACITOR IGBT IGBT CURRENT TRANSFORMER CAPACITOR IGBT IGBT GATE SIGNALS PROTECTION SIGNAL CR1 RELAY DRIVE SIGNAL 18VAC REMOTE RECEPTACLE INVERTEC V250-S POSITIVE OUTPUT TERMINAL SHUNT NEGATIVE OUTPUT TERMINAL THERMOSTATS THERMAL LIGHT CONTROL BOARD LOCAL/ OUTPUT STRIKE MODE REMOTE...

  • Page 28: Main Transformer

    RELAY IGBT CAPACITOR IGBT IGBT CURRENT TRANSFORMER CAPACITOR IGBT IGBT GATE SIGNALS PROTECTION SIGNAL CR1 RELAY DRIVE SIGNAL 18VAC REMOTE RECEPTACLE INVERTEC V250-S POSITIVE OUTPUT TERMINAL SHUNT NEGATIVE OUTPUT TERMINAL THERMOSTATS THERMAL LIGHT CONTROL BOARD LOCAL/ OUTPUT STRIKE MODE REMOTE...

  • Page 29: Output Rectification And Control

    RELAY IGBT CAPACITOR IGBT IGBT CURRENT TRANSFORMER CAPACITOR IGBT IGBT GATE SIGNALS PROTECTION SIGNAL CR1 RELAY DRIVE SIGNAL 18VAC REMOTE RECEPTACLE INVERTEC V250-S POSITIVE OUTPUT TERMINAL SHUNT NEGATIVE OUTPUT TERMINAL THERMOSTATS THERMAL LIGHT CONTROL BOARD LOCAL/ OUTPUT STRIKE MODE REMOTE...

  • Page 30: Protection Circuits

    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. INVERTEC V250-S...

  • Page 31: Insulated Gate Bipolar Transistor (Igbt) Operation

    ON a light switch. FIGURE E.6 IGBT OPERATION GATE BODY REGION DRAIN DRIFT REGION BUFFER LAYER INJECTING LAYER DRAIN B. ACTIVE INVERTEC V250-S Current will flow through the This is similar POSITIVE VOLTAGE APPLIED GATE SOURCE BODY REGION...

  • Page 32: Pulse Width Modulation (Pwm

    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. FIGURE E.7 TYPICAL IGBT OUTPUTS MINIMUM OUTPUT MAXIMUM OUTPUT INVERTEC V250-S . The dwell time (off...

  • Page 33: Pc Board Troubleshooting Procedures

    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 TABLE OF CONTENTS INVERTEC V250-S SECTION F-1...

  • Page 34: How To Use Troubleshooting Guide

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 35: Pc Board Troubleshooting Procedures

    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. INVERTEC V250-S...

  • Page 36: Troubleshooting And Repair

    The machine is dead - no output - no fan. 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.
  • Page 37 No output but the fan operates nor- mally. 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.
  • Page 38 LOCAL control. 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.
  • Page 39 380VAC or higher. 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.
  • Page 40 The machine will not produce more than 200 amps. 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.
  • Page 41 The arc pops out. 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.
  • Page 42 F-10 F-10 NOTES INVERTEC V250-S...

  • Page 43: Auxiliary Transformer Test

    AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.

  • Page 44: Test Procedures

    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 appro- priate leads. See Table F.1 . PLUG J7 INVERTEC V250-S F-12...
  • Page 45 V250-S check the harness wiring to the auxiliary transformer. See wiring diagram. TEST POINT EXPECTED VOLTAGE H2 (4J7) 200 - 208VAC H4 (3J7) 380 - 415VAC H5 (6J7) 440 - 460VAC RED LEAD (3J1) 18VAC (SECONDARY) On Control Board INVERTEC V250-S F-13...
  • Page 46 F-14 F-14 NOTES INVERTEC V250-S...

  • Page 47: Input Rectifier Test

    INPUT RECTIFIER TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 48 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. #207 #207A #209 INVERTEC V250-S F-16...
  • Page 49 Greater than 1000 ohms Greater than 1000 ohms 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 dia- gram and Figure F.2. INVERTEC V250-S F-17...
  • Page 50 F-18 F-18 NOTES INVERTEC V250-S...

  • Page 51: Power Board Resistance Test

    TROUBLESHOOTING & REPAIR POWER BOARD RESISTANCE TEST Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 52 #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. 207A DANGER HIGH VOLTAGE CAN KILL 203A INVERTEC V250-S F-20 202A...
  • Page 53 207A 207A 202A 202A 203A 203A See Power Board Replacement INVERTEC V250-S F-21 Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms Less than 100 ohms Greater than 1000 ohms...
  • Page 54 F-22 F-22 NOTES INVERTEC V250-S...

  • Page 55: Output Diode Test

    OUTPUT DIODES TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 56 LEADS IS MOST IMPORTANT. IF THE TEST LEADS POLARITY IS NOT CORRECT THE TEST WILL HAVE ERRONEOUS RESULTS. SMAW SMAW GTAW THERMAL SOFT CRISP HOT START OUTPUT ARC FORCE LOCAL REMOTE ® INVERTEC V250-S POSITIVE OUTPUT TERMINAL INVERTEC V250-S F-24...
  • Page 57 “leaky”. 7. Perform Filter Capacitor Discharge Procedure detailed in Maintenance Section. INVERTEC V250-S Figure F.5 Meter Probes. 8. Locate output diodes and snubbers. See Figure F.6. for machine codes 10102 and 10103 only. See Figure F.7.

  • Page 58: Output Diodes

    F-26 F-26 TROUBLESHOOTING & REPAIR OUTPUT DIODES TEST (continued) OUTPUT DIODES SNUBBERS Figure F.6 Output Diodes and Snubber Locations (Codes 10102 and 10103) DIODE MODULES Figure F.7 Output Diode Module Locations (Codes 10187 and 10188) INVERTEC V250-S...

  • Page 59: Power Board Voltage Test

    POWER BOARD VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 60 6. Perform the voltage checks outlined in Table F.4 . making sure all of the test conditions are in effect. #313 (5J6) #309 (6J6) #311 (4J6) #308 (1J6) #310 (3J6) #307 (2J6) PLUG J6 V250S POWER G2684 INVERTEC V250-S F-28 PROCEDURE TOUCHING...

  • Page 61: Test Points

    VOLTAGES 14VDC. 14VDC. 7VDC. 7VDC. 12VDC 0 to 1VDC. 15VDC. INVERTEC V250-S F-29 TEST CONDITIONS No load on the machine - the mode switch in SMAW posi- tion. No load on the machine - the mode switch in SMAW posi- tion.
  • Page 62 F-30 F-30 NOTES INVERTEC V250-S...

  • Page 63: Control Board Voltage Test

    CONTROL BOARD VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 64 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. (#375) (#322) (#318) INVERTEC V250-S F-32 PROCEDURE TOUCHING (#303) (BLACK LEAD) (WHITE LEAD) G2666-[ ]...
  • Page 65 18VAC Note: voltage will vary with input line voltage. 0 VDC. 12VDC. 100 mV. 15VDC. INVERTEC V250-S F-33 TEST CONDITIONS The correct input voltage applied to the V250-S and the input power switch (S1) in the ON position. When remote trigger circuit is “closed”.
  • Page 66 F-34 F-34 NOTES INVERTEC V250-S...

  • Page 67: Protection Circuit Test

    PROTECTION CIRCUIT TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 68 J6 on the power board. See Figures F.10. and F.11. V250S CONTROL Control Board Plug J2 Test Points #313 (5J6) #309 (6J6) #311 (4J6) #308 (1J6) #310 (3J6) #307 (2J6) PLUG J6 V250S POWER G2684 Power Board Plug J6 Test Points INVERTEC V250-S F-36 G2666-[ ]...
  • Page 69 If this does not take place the power board may be faulty. Replace. PROTECTION CIRCUIT (SIMPLIFIED) #311 (4J6) (2J2) #313 (8J2) #309 (6J6) (1J2) #310 (3J6) (6J2) INVERTEC V250-S F-37 15VDC leads CONTROL BOARD +15VDC TIMER +15VDC...
  • Page 70 F-38 F-38 NOTES INVERTEC V250-S...

  • Page 71: Capacitor Balance Test

    CAPACITOR BALANCE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 72 ON the V250-S. † Note: This test should only be conducted with the V250-S reconnect switch and “A” jumper configured for 380VAC and above. CAPACITOR (C2) TERMINALS 207A 202A DANGER HIGH VOLTAGE CAN KILL 203A CAPACITOR (C1) TERMINALS INVERTEC V250-S F-40...
  • Page 73 See maintenance section. The capacitors or other components on the power board may be faulty. Replace power board. TABLE F.6 Capacitor Voltages EXPECTED VOLTS DC AT CAPACITOR INPUT APPLIED TERMINALS 460VAC 325VDC 440VAC 311VDC 415VAC 293VDC 380VAC 269VDC INVERTEC V250-S F-41...
  • Page 74 F-42 F-42 NOTES INVERTEC V250-S...

  • Page 75: Control Board Removal And Replacement

    CONTROL BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 76 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. SIX MOUNTING TABS G2666-[ ] DEPRESS LOCKING TAB ON MOUNTING PIN Control Board Plugs and Mounting Pins INVERTEC V250-S F-44...

  • Page 77: Power Board Removal And Replacement

    POWER BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 78 Remove leads #202A, #207A, #203A and #206 from the capacitor terminals. See Figure F.14. Cut any neces- sary cable ties. 207A 202A DANGER HIGH VOLTAGE CAN KILL 203A Power Board Lead Locations INVERTEC V250-S F-46 4 SOCKET HEAD CAP SCREWS...
  • Page 79 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. INVERTEC V250-S F-47...
  • Page 80 F-48 F-48 NOTES INVERTEC V250-S...

  • Page 81: Filter Capacitor Removal And Replacement

    FILTER CAPACITOR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 82 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. MOUNTING BRACKETS POWER BOARD INVERTEC V250-S F-50 disengage REMOVE CASE BACK SCREWS...
  • Page 83 See Figure F.15. 14. Using the 5/16” nut-driver replace configuration the two screws at the top front of the case front panel. See Figure F.15. 15. Perform Replacement Procedure in this section. INVERTEC V250-S F-51 installed) into Power Board...
  • Page 84 F-52 F-52 NOTES INVERTEC V250-S...

  • Page 85: Input Rectifier Bridge Removal And Replacement

    INPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 86 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. CAP HEAD MOUNTING SCREWS #209 INVERTEC V250-S F-54 #207 #207A...
  • Page 87 340 Heat Sink Compound (Lincoln E1868) to the mating surfaces. Torque the mounting cap screws and nuts to 44 IN-LBS. 9. Reconnect the eight leads to the cor- rect terminals and torque the phillips head screws to 31 IN-LBS. INVERTEC V250-S F-55...
  • Page 88 F-56 F-56 NOTES INVERTEC V250-S...

  • Page 89: Output Diode Assembly Removal And Replacement

    (MACHINE CODES BELOW 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.

  • Page 90: Output Diode Assembly Removal And Replacement

    See Figure F.17. 9. With the 5/16” nut-driver remove the two screws from the top rear case back. See Figure F.15 . SNUBBER RESISTORS 7/16 BOLT SLEEVED SPLICES INVERTEC V250-S F-58...

  • Page 91: Locking Tabs

    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 pre- pare unit for reassembly of wrap- around case. INVERTEC V250-S F-59...
  • Page 92 F-60 F-60 NOTES INVERTEC V250-S...

  • Page 93: (Machine Codes Above 10150)

    (MACHINE CODES ABOVE 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 94 (continued) 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 care- ful note of lead placement. 7/16 BOLTED CONNECTIONS INVERTEC V250-S F-62 DIODE MODULES...
  • Page 95 17. Connect the leads to the proper ter- minals and tighten the screws to between 30 to 40 IN-LBS. Do not stress the module terminals when making these connections. 18. Clear all leads and prepare unit for reassembly of wrap-around case. INVERTEC V250-S F-63...
  • Page 96 F-64 F-64 NOTES INVERTEC V250-S...

  • Page 97: Main Transformer Removal And Replacement

    (MACHINE CODES BELOW 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.

  • Page 98: Main Transformer Removal And Replacement

    Upon reassembly the leads must be threaded through correctly. 5. Locate main transformer and associ- ated secondary leads, reactor leads, and shunt connections. See Figure F.21. T3 CURRENT TRANSFORMER INVERTEC V250-S F-66...
  • Page 99 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...
  • Page 100 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. Take note of the by-pass connec- tion on the positive output terminal. INVERTEC V250-S F-68...
  • Page 101 #205 and #208 to the power board. Be sure leads #204 and #205 are routed through the current trans- former (T3) in the correct man- ner. Secure leads with cable ties. 26. Clear all leads and secure for case wrap-around assembly. (continued) INVERTEC V250-S F-69...
  • Page 102 F-70 F-70 NOTES INVERTEC V250-S...

  • Page 103: (Machine Codes Above 10150)

    (MACHINE CODES ABOVE 10150) WARNING Service and repair should be performed only by Lincoln Electric factory trained per- sonnel. 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 precau- tions detailed throughout this manual.
  • Page 104 5. Locate main transformer and associ- ated secondary leads, reactor leads, and shunt connections. See Figure F.24. 6. Disconnect and clear the shunt sensing leads from the control board (plug J4). T3 CURRENT TRANSFORMER INVERTEC V250-S F-72...
  • Page 105 See Figure F.25 . Note: The machine will have to be tilted on its side to gain access to the bottom of the unit. lead INVERTEC V250-S F-73 Label the leads for...
  • Page 106 19. Using the slot head screwdriver and 3/8” nut-driver reassemble the two reactor leads to the output rec- tifier leads. Note lead labels. 20. Replace the sleeving on the reactor connections and replace the cable ties. INVERTEC V250-S F-74...
  • Page 107 #205 and #208 to the power board. Be sure leads #204 and #205 are routed through the current trans- former (T3) in the correct man- ner. Secure leads with cable ties. 26. Clear all leads and secure for case wrap-around assembly. (continued) INVERTEC V250-S F-75...
  • Page 108 F-76 F-76 NOTES INVERTEC V250-S...

  • Page 109: Retest After Repair

    MINIMUM ACCEPTABLE OUTPUT (AT MAXIMUM OUTPUT SETTINGS) MODE OPEN CIRCUIT VOLTAGE RANGE MODE RETEST AFTER REPAIR LESS THAN 2 AMPS LESS THAN 200 WATTS AMPS 1 Amp AMPS 250 Amps INVERTEC V250-S F-77 VOLTS 10 VDC. VOLTS 33 VDC. VOLTS 65 - 80 VDC.
  • Page 110 F-78 F-78 NOTES INVERTEC V250-S...

  • Page 111: Electrical Diagrams

    Control PC Board (G2666) Schematic ......G-6 Power PC Board (G2684) Schematic ......G-7 INVERTEC V250-S...
  • Page 112 NOTES INVERTEC V250-S...

  • Page 113: Electrical Diagrams

    Wiring Diagram (Codes 10102, 10103) N.C. 1600/450 PRIMARY 203A 203A RECONNECT SWITCH 202A 202A POWER 1600/450 207A INPUT INPUT BRIDGE N.A. MOTORS 0.6 AMP SLOW BLOW 200- 208V 220- 230V 380- 415V 440- 460V N.C. AUXILIARY TRANSFORMER NOTES: N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

  • Page 114: Wiring Diagram (Codes 10187, 10188

    Wiring Diagram (Codes 10187, 10188) N.C. 1600/450 PRIMARY 203A 203A RECONNECT SWITCH 202A 202A POWER 1600/450 207A INPUT INPUT BRIDGE N.A. MOTORS 0.6 AMP SLOW BLOW 200- 208V 220- 230V 380- 415V 440- 460V N.C. AUXILIARY TRANSFORMER NOTES: N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

  • Page 115: Electrical Diagrams

    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 in danger to the Machine Operator or Technician.

  • Page 116: Power Pc Board (G2684) Layout

    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 in danger to the Machine Operator or Technician.

  • Page 117: Control Pc Board (G2666) Schematic

    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 in danger to the Machine Operator or Technician.

  • Page 118: Power Pc Board (G2684) Schematic

    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 in danger to the Machine Operator or Technician.

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