Lincoln Electric V250-S User Manual

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SVM124-A

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 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.

July, 1996

View Safety Info View Safety Info View Safety Info View Safety Info

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World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

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

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

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.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.

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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.

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

SAFETY

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

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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.

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.

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.

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Mar ‘95

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.

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.

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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

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

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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

PAGE

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

SECTION-A-1

TECHNICAL 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

INSTALLATION

TABLE OF CONTENTS

-INSTALLATION SECTION-

SECTION-A-1

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INVERTEC V250-S

A-2

INSTALLATION

Technical Specifications - Invertec V250-S

INPUT

THREE PHASE SINGLE PHASE

Standard Input Current

Voltage

208/230/460 34/32/16 60Hz

200/220/400/440 35/33/18/17 50/60 Hz

THREE PHASE SINGLE PHASE

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

RATED OUTPUT

Standard Input Current

Voltage

at Rated Output Model

A-2

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

THREE PHASE SINGLE PHASE

Volts at

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

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

Volts at

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 (6mm2) 10 (6mm2) 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 30 18 10 (6mm2) 10 (6mm2) 440/50/60 30 17 10 (6mm2) 10 (6mm2)

(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.

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(3)

208/60

(3)

230/60

460/60 40 29 10 (6mm2) 10 (6mm2)

200/50/60 80 58 8 (16mm2) 10 (6mm2) 220/50/60 80 58 8 (16mm2) 10 (6mm2) 400/50/60 40 30 10 (6mm2) 10 (6mm2) 440/50/60 40 30 10 (6mm2) 10 (6mm2)

80 59 8 (10mm2) 10 (6mm2) 80 57 8 (10mm2) 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

INVERTEC V250-S

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:

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:

per U.S. National Electrical Code. Connect black, red and white leads to power.

Connect green lead to ground

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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 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).

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 beginning of this chapter for the proper fuse sizes and supply cable sizes.

• Fuse the input circuit with recommended super lag

fuses or delay type circuit breakers.

Technical Specifications

page at the

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.

• 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

S21230

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INVERTEC V250-S

A-5

INSTALLATION

A-5

OUTPUT CONNECTIONS

Refer to figure A.2 for the location of the 6 Pin Remote Receptacle and the Output Terminals.

SMAW

6 PIN REMOTE RECEPTACLE

SOFT

REMOTE

GTAW

CRISP

LOCAL

THERMAL

120

OUTPUT

250

INVERTEC V250-S

HOT START

170

ARC FORCE

230

QUICK DISCONNECT PLUGS

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

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.

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).

Length Cable Size up to 150 ft.(46m) 1/0 (50mm2) up to 250 ft.(72m) 2/0 (70mm2)

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.

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.

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INVERTEC V250-S

A-6

NOTES

A-6

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INVERTEC V250-S

OPERATION

SECTION-B-1SECTION-B-1

TABLE OF CONTENTS

-OPERATION SECTION-

SAFETY 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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INVERTEC V250-S

B-2

OPERATION

B-2

Read and understand this entire section before operating your machine.

SAFETY INSTRUCTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

____________________________________

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

____________________________________

WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion

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).

OPERATIONAL FEATURES

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.

WELDING CAPABILITY

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.

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.

____________________________________

Only qualified personnel should operate this equipment. Observe all safety information throughout this manual.

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• Keep flammable material away.

• Do not weld, cut or gouge on

containers that have held com-

bustibles.

ARC RAYS can burn.

• Wear eye, ear and body protection.

INVERTEC V250-S

B-3

OPERATION

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.

SMAW

SOFT

GTAW

SMAW CRISP

THERMAL

OUTPUT

REMOTE

LOCAL

120

INVERTEC V250-S

250

170

230

HOT START

ARC FORCE

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 elec-

trodes. 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.

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INVERTEC V250-S

B-4

OPERATION

B-4

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

FULL RANGE IS 1-10. 1 is VERY SOFT,

10 IS VERY CRISP

Nominal Recommended

Mode Process Setting Adjustment Range

CC SMAW 1 EXX18 thru 5 1 (gentle, may stick) to 9

(soft) EXX28 stick (forceful, more spatter)

CC SMAW 2 EXX10 thru 6 3 to 10

(crisp) EXX14 stick

Air Carbon Arc 1 None

Cutting

7. Output Terminals - These quick disconnect terminals provide connection points for the electrode and work cables. Refer to 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.

Output Connections

in the

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

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.

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

Touch starting is done as follows:

Accessories

section of this manual.

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 chapter.

Thermal Protection

later in this

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

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INVERTEC V250-S

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.

B-5

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.

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INVERTEC V250-S

B-6

NOTES

B-6

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INVERTEC V250-S

SECTION C-1

OPTIONS / ACCESSORIES........................................................................................................C-2

CABLE PLUGS......................................................................................................................C-2

REMOTE CONTROLS ..........................................................................................................C-2

ACCESSORIES

SECTION C-1

TABLE OF CONTENTS

-ACCESSORIES SECTION-

K852-70 .......................................................................................................................C-2

K852-95 .......................................................................................................................C-2

K857.............................................................................................................................C-2

K963 ............................................................................................................................C-2

K870.............................................................................................................................C-2

K814 ............................................................................................................................C-2

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INVERTEC V250-S

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.

REMOTE CONTROLS

K857 - Remote Output Control for stick welding. K963 - Hand Amptroltmfor 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.

C-2

K870 - Foot Amptroltmfor 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.

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INVERTEC V250-S

SECTION D-1

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE.........................................................D-2

ROUTINE MAINTENANCE..........................................................................................................D-3

FILTER CAPACITOR CONDITIONING ......................................................................................D-3

LOCATION OF MAINTENANCE COMPONENTS.......................................................................D-4

MAINTENANCE

TABLE OF CONTENTS

-MAINTENANCE SECTION-

SECTION D-1

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INVERTEC V250-S

D-2

MAINTENANCE

D-2

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.

---------------------------------------------------------------------

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

1. Turn off input power or disconnect input power lines.

2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-around machine cover.

3. Be careful not to make contact with the capacitor terminals that are located in the top and bottom of the Power Board.

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.

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.

7. Repeat discharge procedure for the capacitor on

other two terminals.

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.

FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.

POWER

BOARD

RIGHT SIDE OF MACHINE

CAP ACIT OR TERMINALS

UPPER 

LOWER  CAPACITOR  TERMINALS

POWER

RESISTOR

INSULATED

PLIERS

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INSULATED

GLOVES

INVERTEC V250-S

D-3

MAINTENANCE

D-3

ROUTINE MAINTENANCE

1. 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.

2. Remove the machine wrap-around cover and perform the input filter capacitor discharge procedure (detail at the beginning of this chapter).

3. 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

• Input Filter Capacitors

• Output Terminals

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.

4. Examine capacitors for leakage or oozing. Replace if needed.

5. Examine the sheet metal case for dents or break-

age. 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.

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INVERTEC V250-S

D-4

MAINTENANCE

FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.

D-4

CONTROL PC BOARD

POWER SWITCH

OUTPUT TERMINALS

OUTPUT RECTIFIER HEATSINK FINS

INPUT RECTIFIER

POWER PC BOARD

COOLING FANS

MAIN TRANSFORMER

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AUXILIARY TRANSFORMER

INVERTEC V250-S

E-1

THEORY OF OPERATION

TABLE OF CONTENTS

-THEORY OF OPERATION SECTION-