Lincoln Electric IM490 User Manual
IM490-C
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INVERTEC V250-S
For use with machines having Code Numbers:
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.
™
10102, 10103, 10187, 10188, 10304,
February, 2001
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
OPERATOR’S MANUAL
ISO 9001
ANSI RAB
QMS
Copyright © 2001 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i
SAFETY
i
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
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.
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.
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
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.
____________________________________________________
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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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.
___________________________________________________
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.
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
ii
SAFETY
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.
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.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
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.
5.e. Also see item 1.b.
Mar ‘95
vapors
to
iii
SAFETY
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.
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.
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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.
Mar ‘95
iv
SAFETY
iv
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.
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.
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.
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
place.
Mar. ‘93
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
and Equipment For Damage Immediately
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
INVERTEC V250-S
TABLE OF CONTENTS
PAGE
INSTALLATION .......................................................................................................................SECTION A
TECHNICAL SPECIFICATIONS ........................................................................................A-1 & 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-1
GENERAL DESCRIPTION...........................................................................................................B-1
CONTROLS AND SETTINGS......................................................................................................B-2
CONSTANT CURRENT PROCESSES........................................................................................B-3
PARALLEL OPERATION .............................................................................................................B-4
OVERLOAD PROTECTION.........................................................................................................B-4
THERMAL PROTECTION............................................................................................................B-4
ACCESSORIES .......................................................................................................................SECTION C
OPTIONS / ACCESSORIES ........................................................................................................C-1
CABLE PLUGS......................................................................................................................C-1
REMOTE CONTROLS ..........................................................................................................C-1
vi
MAINTENANCE .......................................................................................................................SECTION D
INPUT FILTER CAPACITOR DISCHARGE PROCEDURE.........................................................D-1
ROUTINE MAINTENANCE..........................................................................................................D-2
FILTER CAPACITOR CONDITIONING ......................................................................................D-2
LOCATION OF MAINTENANCE COMPONENTS.......................................................................D-3
TROUBLESHOOTING................................................................................................................SECTION E
PC BOARD TROUBLESHOOTING PROCEDURES.............................................................E-1
TROUBLESHOOTING GUIDE ..............................................................................................E-2
DIAGRAMS ........................................................................................................................SECTION F
PARTS MANUAL ...................................................................................................................P-244 SERIES
INVERTEC V250-S
A-1
INSTALLATION
Technical Specifications - Invertec V250-S - K1436-1, K1437-1 & K1437-3
INPUT
THREE PHASE SINGLE PHASE
Standard Input Current
Voltage
at Rated Output Model
208/230/460 60Hz 34/32/16 60Hz
200/220/400/440 50/60Hz 35/33/18/17 50/60 Hz
380-415 50Hz 20/18 50Hz
RATED OUTPUT
THREE PHASE SINGLE PHASE
Standard Input Current
Voltage
at Rated Output Model
208/230/460 60Hz 59/57/29 60Hz
200/220/400/440 50/60 Hz 58/58/30/30 50/60 Hz
A-1
Volts at
Duty Cycle
(1)
Amps Rated Amps Model
35% Duty Cycle 250 30 60Hz
60% Duty Cycle 200 28-32 60Hz
100% Duty Cycle 165 26.5 60Hz
35% Duty Cycle 250 28†-30 50/60Hz
60% Duty Cycle 200 29-32 50/60Hz
100% Duty Cycle 165 26.5 50/60Hz
35% Duty Cycle 250 30 50Hz
60% Duty Cycle 200 28 50Hz
100% Duty Cycle 165 26 50Hz
THREE PHASE SINGLE PHASE
Welding Constant Open
Current Range
Circuit Voltage
1-250 Amps 65-80 VDC
RECOMMENDED INPUT WIRE AND FUSE SIZES
THREE PHASE SINGLE PHASE
Type 75°C
Type 75°C Copper
Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency
(2)
Size Nameplate Sizes Sizes
Volts at
Duty Cycle
(1)
Amps Rated Amps Model
35% Duty Cycle 250 27†-30 60Hz
60% Duty Cycle 200 28-32 60Hz
100% Duty Cycle 165 26.5 60Hz
35% Duty Cycle 250 26†-30 50/60Hz
60% Duty Cycle 200 28-32 50/60Hz
100% Duty Cycle 165 26.5 50/60Hz
OUTPUT
Welding Constant Open
Current Range
1-250 Amps 65-80 VDC
Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency
(2)
Size Nameplate Sizes Sizes
Circuit Voltage
Type 75°C Copper
Type 75°C
208/60 50 34 10 (6mm
230/60 50 32 10(6mm2) 10 (6mm2)
460/60 30 16 10 (6mm2) 10 (6mm2)
200/50/60 50 35 10 (6mm
220/50/60 50 33 10 (6mm2) 10 (6mm2)
400/50/60 30 18 12 (4mm2) 12 (4mm2)
440/50/60 30 17 12 (4mm2) 12 (4mm2)
2
) 10 (6mm2)
2
) 10 (6mm2)
(3)
208/60
(3)
230/60
460/60 40 29 10 (6mm2) 10 (6mm2)
200/50/60 80 58 8 (8.4mm
220/50/60 80 58 8 (8.4mm2) 10 (6mm2)
400/50/60 40 30 10 (6mm2) 10 (6mm2)
440/50/60 40 30 10 (6mm2) 10 (6mm2)
80 59 8 (8.4mm2) 10 (6mm2)
80 57 8 (8.4mm2) 10 (6mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight
15.0 in. 9.1 in. 19.7 in. 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.
(†)
200 & 208VAC input may not meet NEMA/IEC specifications at 250 Amps.
INVERTEC V250-S
2
) 10 (6mm2)
A-2
INSTALLATION
Technical Specifications - Invertec V250-S - K1437-2
INPUT
THREE PHASE SINGLE PHASE
Standard Input Current
Voltage
at Rated Output Model
220/440 35% Duty Cycle 34/17 50/60 Hz
400 60% Duty Cycle 16 50/60 Hz
220/400/440 100% Duty Cycle
19/11/9 50/60 Hz
RATED OUTPUT
THREE PHASE SINGLE PHASE
Standard Input Current
Voltage
220/440 35% Duty Cycle 57/29 50/60 Hz
400 60% Duty Cycle 27 50/60 Hz
220/400/440 100% Duty Cycle
A-2
at Rated Output Model
34/21/17 50/60 Hz
Duty Cycle
(1)
35% Duty Cycle
Amps Rated Amps Model
(3)
250 30V 50/60Hz
60% Duty Cycle 200 28V 50/60Hz
100% Duty Cycle 155 26.2V 50/60Hz
THREE PHASE SINGLE PHASE
Volts at
Welding Constant Open
Current Range
Circuit Voltage
RECOMMENDED INPUT WIRE AND FUSE SIZES
THREE PHASE SINGLE PHASE
Type 75°C
Type 75°C Copper
Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency
(2)
Size Nameplate Sizes Sizes
Duty Cycle
(1)
35% Duty Cycle
Amps Rated Amps Model
(3)
230 29V 50/60Hz
60% Duty Cycle 190 27.6V 50/60Hz
100% Duty Cycle 155 26.2V 50/60Hz
OUTPUT
Welding Constant Open
Volts at
Current Range
Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency
(2)
Size Nameplate Sizes Sizes
Circuit Voltage
Type 75°C Copper
Type 75°C
208/60 50 34 10 (6mm
230/60 50 32 10(6mm2) 10 (6mm2)
460/60 30 16 10 (6mm2) 10 (6mm2)
200/50/60 50 35 10 (6mm2) 10 (6mm2)
220/50/60 50 33 10 (6mm2) 10 (6mm2)
400/50/60 20 18 12 (4mm2) 12 (4mm2)
440/50/60 20 17 12 (4mm2) 12 (4mm2)
2
) 10 (6mm2)
PHYSICAL DIMENSIONS
Height Width Depth Weight
15.0 in. 9.1 in. 19.7 in. 41 lbs.
381 mm 231 mm 500 mm 19 Kg
(1) Based on a 10 min. period.
(2) Input voltage must be within ±10% of rated value.
(3) Excluding 400V-VAC Input
INVERTEC V250-S
(3)
208/60
(3)
230/60
460/60 40 29 10 (6mm2) 10 (6mm2)
200/50/60 80 58 8 (8.4mm2) 10 (6mm2)
220/50/60 80 58 8 (8.4mm2) 10 (6mm2)
400/50/60 40 30 10 (6mm2) 10 (6mm2)
440/50/60 40 30 10 (6mm2) 10 (6mm2)
80 59 8 (8.4mm2) 10 (6mm2)
80 57 8 (8.4mm2) 10 (6mm2)
A-3
INSTALLATION
A-3
Read this entire installation section before you
start installation.
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.
• 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
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.
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.
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.
GROUND CONNECTION
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
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.
• 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.
STACKING
V250-S’s cannot be stacked.
TILTING
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.
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.
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
A-4
INSTALLATION
A-4
POWER INPUT CONNECTION FOR 50/60 HZ
MACHINES
1. Connect terminal marked to earth ground
per National Electric Code.
2. Connect the supply lines to the line switch. Torque
to 3.0 Nm.
3. Install in accordance with all local and national
electric codes.
The Invertec V250-S 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. On K1436-1, K1437-1 and
K1437-3, the cord connector is designed for a cord
diameter of 7.9 to 27.2mm (.310 to 1.070 in). On
K1437-2 the cord connector is designed for a cord
diameter of 11.4 to 20.0mm (.450 to .790 in).
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.
INPUT FUSE AND SUPPLY WIRE
Refer to the Technical Specifications page at the
beginning of this chapter for the proper fuse sizes and
supply cable sizes.
INPUT VOLTAGE RECONNECT
PROCEDURE
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.
CAUTION
Failure to follow these instructions can cause immediate failure of components within the welder.
------------------------------------------------------------------------
1. Open the access door on the right side of the
machine.
2. For 200-230: Position the large switch to 200-230.
For 380-460: Position the large switch to 380-460.
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.
• Install the proper fuse in the fuse holder in the main
disconnect panel.
RECONNECT PROCEDURE
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD 'A' TO DESIRED
INPUT VOLTAGE RANGE.
440-460V
380-415V
220-230V
200-208V
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
VOLTAGE=380-460V
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
Figure A.1 Input Voltage Reconnect Instructions
'A'
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
REPLACE WITH SPECIFIED FUSE.
.
Disconnect input power before
inspecting or servicing machine.
.
Do not operate with wraparound
removed.
.
Do not touch electrically live parts.
.
Only qualified persons should install,
use or service this equipment.
VOLTAGE=200-230V
A
S21230
INVERTEC V250-S
A-5
OUTPUT CONNECTIONS
INSTALLATION
QUICK DISCONNECT PLUGS
A-5
Refer to figure A.2 for the location of the 6 Pin Remote
Receptacle and the Output Terminals.
FIGURE A.2 OUTPUT CONNECTIONS
SMAW
SMAW
6 PIN
REMOTE
RECEPTACLE
GTAW
SOFT
CRISP
LOCAL
REMOTE
-
OUTPUT TERMINALS
THERMAL
A
120
85
OUTPUT
50
15
1
250
INVERTEC V250-S
+
HOT START
5
6
4
3
2
1
0
170
ARC FORCE
230
5
6
4
3
2
1
0
¤
I
O
7
8
9
10
7
8
9
10
S
A quick disconnect system is used for the welding
cable connections. The welding plug included with the
machine is designed to accept a welding cable size of
1/0 to 2/0.
1. Remove 1 in. (25mm) of welding cable insulation.
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.
BOOT
WELDING CABLE
25 mm
1 in.
TRIM
3. Slide the copper tube into the brass plug.
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.
Note: A minor modification is needed when K963
Hand Amptrol is used with the V250-S. The braided
grounding strap must be disconnected from connector
body on end of cable that attaches to machine.
Remove cable clamp screw securing grounding strap,
remove strap, and reinstall screw. Run grounding
strap along side of cable so that it does not contact
connector body, and secure in place with electrical
tape. This modification is necessary in order to avoid
coupling electrical noise from the case of the machine
onto the control leads, which would otherwise result in
poor starting and unstable welding performance.
OUTPUT CABLES
Select the output cable size based on Table A.1.
TABLE A.1
Cable Sizes for Combined Length of Electrode and
Work Cable ( Copper Cable Rated at 75°C).
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.
SET SCREW
BRASS PLUG
COPPER TUBE
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.
Length Cable Size
up to 150 ft.(46m) 1/0 (50mm
up to 250 ft.(72m) 2/0 (70mm2)
2
)
INVERTEC V250-S
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