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Lincoln Electric INVERTEC V250-S User Manual

Lincoln Electric INVERTEC V250-S
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INVERTEC V250-S
SERVICE MANUAL
Sales and Service through Subsidiaries and Distributors Worldwide
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100
World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors
SVM124-A
July, 1996
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful 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.
For use with machine Code Numbers 10102 to 10188
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Table of Contents

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Lincoln Electric INVERTEC V250-S Specifications

General IconGeneral
Input Frequency50/60 Hz
Output Current Range5-250 A
Output Voltage Range10 - 30 V
ProcessesStick, TIG
Power Factor0.93
Efficiency85%
Input Phase3
Rated Output250 A at 28 V
Duty Cycle60% at 250 A

Summary

SAFETY

CALIFORNIA PROPOSITION 65 WARNINGS

State-specific warnings regarding diesel and gasoline engine exhaust.

ELECTRIC SHOCK HAZARDS

Warnings and precautions to prevent electrocution during operation and maintenance.

FUMES AND GASES HAZARDS

Risks associated with breathing welding fumes and gases, and ventilation requirements.

ARC RAYS AND SPARKS HAZARDS

Dangers from arc rays, sparks, and spatter, with protective measures.

CYLINDER EXPLOSION HAZARDS

Precautions for handling compressed gas cylinders to prevent explosions.

ELECTRICALLY POWERED EQUIPMENT SAFETY

Safety guidelines for equipment connected to electrical power sources.

INSTALLATION

TECHNICAL SPECIFICATIONS

Detailed technical data including input/output ratings and physical dimensions.

SAFETY PRECAUTIONS

Essential safety guidelines to follow before and during installation.

SITE SELECTION AND ENVIRONMENTAL CONSIDERATIONS

Guidelines for choosing an appropriate operating environment, including location, stacking, and HF precautions.

INPUT POWER CONNECTIONS

Instructions for connecting input power, including voltage reconnection and wire/fuse sizes.

OUTPUT CONNECTIONS

Guidance on connecting output cables, remote controls, and using quick disconnect plugs.

OPERATION

SAFETY INSTRUCTIONS

Critical safety warnings for operating the welding machine.

GENERAL DESCRIPTION AND FEATURES

Overview of the machine's capabilities, including output control and welding modes.

CONTROLS AND SETTINGS

Explanation of the front panel controls and their functions for operation.

OPERATING MODES AND PROCESSES

Details on using the machine for SMAW, TIG, and air carbon arc cutting, including settings.

MACHINE PROTECTION AND OPERATION MODES

Information on parallel operation, overload protection, thermal shutdown, and arc force settings.

ACCESSORIES

OPTIONS / ACCESSORIES OVERVIEW

Listing of available optional accessories for the machine.

CABLE PLUGS

Details on cable plug kits for quick disconnect connections.

REMOTE CONTROLS

Information on various remote control devices for adjusting output.

MAINTENANCE

ROUTINE MAINTENANCE SCHEDULE

Recommended maintenance tasks and their frequency for optimal performance.

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

Step-by-step procedure for safely discharging input filter capacitors.

FILTER CAPACITOR CONDITIONING

Process for conditioning filter capacitors, especially after extended storage.

LOCATION OF MAINTENANCE COMPONENTS

Visual guide to the location of key components requiring maintenance.

THEORY OF OPERATION

GENERAL DESCRIPTION AND INPUT VOLTAGE

Overview of the machine's function and input power configuration.

PRE-CHARGE AND PROTECTION CIRCUITS

Explanation of the pre-charge process and protective circuit functions.

MAIN TRANSFORMER AND OUTPUT STAGES

How the main transformer and output rectification control the welding current.

IGBT AND PWM OPERATION

Principles behind Insulated Gate Bipolar Transistor (IGBT) and Pulse Width Modulation (PWM) control.

TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

Instructions on how to effectively use the troubleshooting guide.

PC BOARD TROUBLESHOOTING PROCEDURES

Procedures for diagnosing and replacing printed circuit boards.

OUTPUT PROBLEMS DIAGNOSIS

Troubleshooting steps for various output-related issues such as no output or intermittent output.

WELDING PROBLEMS DIAGNOSIS

Troubleshooting steps for poor welding performance or arc instability.

COMPONENT TEST PROCEDURES

Detailed tests for diagnosing specific components like transformers, rectifiers, and diodes.

COMPONENT REMOVAL AND REPLACEMENT

Step-by-step guides for removing and replacing major internal components.

RETEST AFTER REPAIR

Requirements for retesting the machine after repairs or component replacements.

ELECTRICAL DIAGRAMS

WIRING DIAGRAMS

Schematics detailing internal wiring for different machine codes.

PC BOARD LAYOUTS AND SCHEMATICS

Visual guides and schematics for the control and power printed circuit boards.

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