RETURN TO MAIN INDEX
IM490-C
INVERTEC â„? V250-S February, 2001
10102, 10103, 10187, 10188, 10304,
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 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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
Copyright © 2001 Lincoln Global Inc.
CERTIFICATE NUMBER: 30273
� 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 i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
6. Eloigner les matériaux inflammables ou les recouvrir afin de
dans ce manuel aussi bien que les précautions de sûreté
prévenir tout risque d’incendie dû aux étincelles.
générales suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines à soud-
vapeurs du solvant pour produire du phosgéne (gas forte-
er parce que la tension entre les deux pinces peut être le
ment toxique) ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
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 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché Ã
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
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:
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
vi
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
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 A-1
INSTALLATION
Technical Specifications - Invertec V250-S - K1436-1, K1437-1 & K1437-3
INPUT
THREE PHASE SINGLE PHASE
Standard Input Current Standard Input Current
Voltage at Rated Output Model Voltage at Rated Output Model
208/230/460 60Hz 34/32/16 60Hz 208/230/460 60Hz 59/57/29 60Hz
200/220/400/440 50/60Hz 35/33/18/17 50/60 Hz 200/220/400/440 50/60 Hz 58/58/30/30 50/60 Hz
380-415 50Hz 20/18 50Hz
RATED OUTPUT
THREE PHASE SINGLE PHASE
Volts at Volts at
Duty Cycle(1) Duty Cycle(1)
Amps Rated Amps Model Amps Rated Amps Model
27�-30
35% Duty Cycle 250 30 60Hz 35% Duty Cycle 250 60Hz
60% Duty Cycle 200 28-32 60Hz 60% Duty Cycle 200 28-32 60Hz
100% Duty Cycle 165 26.5 60Hz 100% Duty Cycle 165 26.5 60Hz
28�-30 26�-30
35% Duty Cycle 250 50/60Hz 35% Duty Cycle 250 50/60Hz
60% Duty Cycle 200 29-32 50/60Hz 60% Duty Cycle 200 28-32 50/60Hz
100% Duty Cycle 165 26.5 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
OUTPUT
THREE PHASE SINGLE PHASE
Welding Constant Open Welding Constant Open
Current Range Circuit Voltage Current Range Circuit Voltage
1-250 Amps 65-80 VDC 1-250 Amps 65-80 VDC
RECOMMENDED INPUT WIRE AND FUSE SIZES
THREE PHASE SINGLE PHASE
Type 75°C Type 75°C
Type 75°C Copper Type 75°C Copper
Fuse Input Copper Ground Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in (Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC) Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency(2) Size Nameplate Sizes Sizes Frequency(2) Size Nameplate Sizes Sizes
208/60 50 34 10 (6mm2) 10 (6mm2) 208/60(3) 80 59 8 (8.4mm2) 10 (6mm2)
230/60 50 32 10(6mm2) 10 (6mm2) 230/60(3) 80 57 8 (8.4mm2) 10 (6mm2)
460/60 30 16 10 (6mm2) 10 (6mm2) 460/60 40 29 10 (6mm2) 10 (6mm2)
200/50/60 50 35 10 (6mm2) 10 (6mm2) 200/50/60 80 58 8 (8.4mm2) 10 (6mm2)
220/50/60 50 33 10 (6mm2) 10 (6mm2) 220/50/60 80 58 8 (8.4mm2) 10 (6mm2)
400/50/60 30 18 12 (4mm2) 12 (4mm2) 400/50/60 40 30 10 (6mm2) 10 (6mm2)
440/50/60 30 17 12 (4mm2) 12 (4mm2) 440/50/60 40 30 10 (6mm2) 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
A-2 A-2
INSTALLATION
Technical Specifications - Invertec V250-S - K1437-2
INPUT
THREE PHASE SINGLE PHASE
Standard Input Current Standard Input Current
Voltage at Rated Output Model Voltage at Rated Output Model
220/440 35% Duty Cycle 34/17 50/60 Hz 220/440 35% Duty Cycle 57/29 50/60 Hz
400 60% Duty Cycle 16 50/60 Hz 400 60% Duty Cycle 27 50/60 Hz
220/400/440 100% Duty Cycle 19/11/9 50/60 Hz 220/400/440 100% Duty Cycle 34/21/17 50/60 Hz
RATED OUTPUT
THREE PHASE SINGLE PHASE
Volts at Volts at
(1) (1)
Duty Cycle Amps Rated Amps Model Duty Cycle Amps Rated Amps Model
35% Duty Cycle(3) 35% Duty Cycle(3)
250 30V 50/60Hz 230 29V 50/60Hz
60% Duty Cycle 200 28V 50/60Hz 60% Duty Cycle 190 27.6V 50/60Hz
100% Duty Cycle 155 26.2V 50/60Hz 100% Duty Cycle 155 26.2V 50/60Hz
OUTPUT
THREE PHASE SINGLE PHASE
Welding Constant Open Welding Constant Open
Current Range Circuit Voltage Current Range Circuit Voltage
RECOMMENDED INPUT WIRE AND FUSE SIZES
THREE PHASE SINGLE PHASE
Type 75°C Type 75°C
Type 75°C Copper Type 75°C Copper
Fuse Input Copper Ground Fuse Input Copper Ground
(Superlag) Ampere Wire in Wire in (Superlag) Ampere Wire in Wire in
Input or Rating Conduit Conduit Input or Rating Conduit Conduit
Voltage Breaker on AWG (IEC) AWG (IEC) Voltage Breaker on AWG (IEC) AWG (IEC)
Frequency(2) Size Nameplate Sizes Sizes Frequency(2) Size Nameplate Sizes Sizes
208/60 50 34 10 (6mm2) 10 (6mm2) 208/60(3) 80 59 8 (8.4mm2) 10 (6mm2)
230/60 50 32 10(6mm2) 10 (6mm2) 230/60(3) 80 57 8 (8.4mm2) 10 (6mm2)
460/60 30 16 10 (6mm2) 10 (6mm2) 460/60 40 29 10 (6mm2) 10 (6mm2)
200/50/60 50 35 10 (6mm2) 10 (6mm2) 200/50/60 80 58 8 (8.4mm2) 10 (6mm2)
220/50/60 50 33 10 (6mm2) 10 (6mm2) 220/50/60 80 58 8 (8.4mm2) 10 (6mm2)
400/50/60 20 18 12 (4mm2) 12 (4mm2) 400/50/60 40 30 10 (6mm2) 10 (6mm2)
440/50/60 20 17 12 (4mm2) 12 (4mm2) 440/50/60 40 30 10 (6mm2) 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
A-3 A-3
INSTALLATION
Read this entire installation section before you HIGH FREQUENCY PRECAUTIONS
start installation.
If possible locate the V250-S away from radio con-
trolled machinery. The normal operation of the
SAFETY PRECAUTIONS V250-S may adversely affect the operation of RF con-
trolled equipment, which may result in bodily injury or
damage to the equipment.
WARNING
INPUT CONNECTIONS
ELECTRIC SHOCK can kill.
� Have an electrician install and ser-
vice this equipment. The Invertec V250-S should be connected only by a
qualified electrician. Installation should be made in
� Turn the input power off at the fuse accordance with all local and national electric codes
box before working on equipment. and the information detailed below.
� Do not touch electrically hot parts.
GROUND CONNECTION
� Be sure to discharge capacitors with
the procedure outlined in the
Maintenance Section of this manual Ground per National Electrical Code for 60Hz
before working in that area of the machines connect the green lead to earth ground.
equipment. 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.
SELECT SUITABLE LOCATION
INPUT SUPPLY CONNECTIONS
The Invertec V250-S will operate in harsh environ-
ments. Even so, it is important that simple preventa- Be sure the voltage phase and frequency of the input
tive measures are followed in order to assure long life power is as specified on the rating plate, located on
and reliable operation. the rear of the machine.
� The machine must be located where there is free cir- Supply line entry provision is in the case rear panel.
culation of clean air such that air movement in the
back and out the front will not be restricted.
POWER INPUT CONNECTION FOR 60HZ
� Dirt and dust that can be drawn into the machine MACHINES
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating A 10 ft. power cord is provided and wired into the
temperatures and nuisance shutdown. machine. Follow the power cord connection instruc-
tions. Incorrect connection may result in equipment
� Keep machine dry. Shelter from rain and snow. Do damage.
not place on wet ground or in puddles.
Single Phase Input: Connect green lead to ground
STACKING per U.S. National Electrical Code. Connect black and
white leads to power. Wrap red lead with tape to pro-
V250-S’s cannot be stacked. vide 600V insulation.
TILTING Three Phase Input: Connect green lead to ground
per U.S. National Electrical Code. Connect black, red
and white leads to power.
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.
INVERTEC V250-S
A-4 A-4
INSTALLATION
POWER INPUT CONNECTION FOR 50/60 HZ INPUT VOLTAGE RECONNECT
MACHINES
PROCEDURE
1. Connect terminal marked to earth ground
When received directly from the factory, units are con-
per National Electric Code.
nected for the highest input voltage, 440 VAC for
2. Connect the supply lines to the line switch. Torque
50/60 Hz machines and 460 VAC for 60 Hz machines.
to 3.0 Nm.
If 440 or 460 VAC is the desired input, then the
3. Install in accordance with all local and national
machine may be connected to the power system with-
electric codes.
out any setup required inside the reconnect door.
However, verify the connection with the following pro-
The Invertec V250-S machine is supplied with one
cedure. For other voltages refer to the instructions
cord connector. The cord connector provides a strain
located on the Reconnect Panel Access Door or fol-
relief for the input power cord as it passes it through
low the instructions below.
the rear access hole. On K1436-1, K1437-1 and
K1437-3, the cord connector is designed for a cord
CAUTION
diameter of 7.9 to 27.2mm (.310 to 1.070 in). On
K1437-2 the cord connector is designed for a cord
Failure to follow these instructions can cause immedi-
diameter of 11.4 to 20.0mm (.450 to .790 in).
ate failure of components within the welder.
------------------------------------------------------------------------
Strip away outer jacket of cord, trim fillers and insert
conductors through cord connector. The jacketed por-
1. Open the access door on the right side of the
tion of the cord must go through the cord connector.
machine.
Tighten both connector screws.
2. For 200-230: Position the large switch to 200-230.
INPUT FUSE AND SUPPLY WIRE
For 380-460: Position the large switch to 380-460.
Refer to the Technical Specifications page at the
3. Move the “A� lead to the appropriate terminal.
beginning of this chapter for the proper fuse sizes and
Refer to figure A.1 below.
supply cable sizes.
� 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
. Disconnect input power before
1. BE SURE POWER SWITCH IS OFF. inspecting or servicing machine.
.
2. CONNECT LEAD 'A' TO DESIRED Do not operate with wraparound
removed.
INPUT VOLTAGE RANGE.
. Do not touch electrically live parts.
440-460V
Only qualified persons should install,
.
'A' use or service this equipment.
380-415V
220-230V
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
200-208V
REPLACE WITH SPECIFIED FUSE.
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
VOLTAGE=380-460V VOLTAGE=200-230V
S21230
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. A
Figure A.1 Input Voltage Reconnect Instructions
INVERTEC V250-S
A-5 A-5
INSTALLATION
OUTPUT CONNECTIONS QUICK DISCONNECT PLUGS
A quick disconnect system is used for the welding
Refer to figure A.2 for the location of the 6 Pin Remote
cable connections. The welding plug included with the
Receptacle and the Output Terminals.
machine is designed to accept a welding cable size of
FIGURE A.2 OUTPUT CONNECTIONS
1/0 to 2/0.
1. Remove 1 in. (25mm) of welding cable insulation.
SMAW SMAW
GTAW THERMAL
HOT START
SOFT CRISP
5 6
4
2. Slide rubber boot onto cable end. The boot end
7
3
8
2
A
may be trimmed to match the cable diameter.
120
85
6 PIN 9
1
OUTPUT
0
REMOTE Soap or other lubricant will help to slide the boot
170 10
50
RECEPTACLE
over the cable.
15 ARC FORCE
230
LOCAL
REMOTE 5 6
1 4
7
3
250 8
2
9
1
0
10
BOOT
¤
WELDING CABLE
INVERTEC V250-S
S
+
- I
25 mm
TRIM
1 in.
O
OUTPUT TERMINALS
3. Slide the copper tube into the brass plug.
REMOTE CONTROL RECEPTACLE 4. Insert cable into copper tube.
5. Tighten set screw to collapse copper tube. Screw
Remote control (K857), Arc start switch (K814), Hand
must apply pressure against welding cable. The
amptrol (K963) and Foot amptrol (K870) connect
top of the set screw will be well below the surface
directly to 6 pin amphenol on the front of the unit.
of the brass plug after tightening.
Note: A minor modification is needed when K963
Hand Amptrol is used with the V250-S. The braided
SET SCREW
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 BRASS PLUG
tape. This modification is necessary in order to avoid COPPER TUBE
coupling electrical noise from the case of the machine
onto the control leads, which would otherwise result in
poor starting and unstable welding performance.
6. Slide rubber boot over brass plug. The rubber
boot must be positioned to completely cover all
OUTPUT CABLES
electrical surfaces after the plug is locked into the
receptacle.
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)
INVERTEC V250-S
B-1 B-1
OPERATION
Read and understand this entire section before GENERAL DESCRIPTION
operating your machine.
The Invertec V250-S is a 250 amp arc welding power
SAFETY INSTRUCTIONS source that utilizes single or three phase input power,
to produce constant current output. The welding
WARNING response of this Invertec has been optimized for stick
(SMAW) and TIG (GTAW).
ELECTRIC SHOCK can kill.
OPERATIONAL FEATURES
� Do not touch electrically live parts such
The Invertec V250-S provides continuous total range
as output terminals or internal wiring.
output current adjustment, selectable welding modes
and local or remote output control. Welding character-
� Insulate yourself from the work and
istics can be controlled via an arc force control.
ground.
Additionally, starting characteristics can be adjusted
via a “hot start� control.
� Always wear dry insulating gloves.
____________________________________
WELDING CAPABILITY
FUMES AND GASES
can be dangerous.
The Invertec V250-S is rated at 250 amps, 35% duty
cycle (based on a 10 minute cycle). It is also rated at
� Keep your head out of fumes.
165 amps, 100% duty cycle, and 200 amps, 60% duty
cycle.
� Use ventilation or exhaust to
remove fumes from breathing LIMITATIONS
zone.
The V250-S is not recommended for pipe thawing.
____________________________________
The V250-S should not be powered from the auxiliary
WELDING, CUTTING and
power supply of an engine welder. Special protection
GOUGING SPARKS circuits may operate causing loss of output.
can cause fire or explosion
� 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.
____________________________________
Only qualified personnel should operate this equip-
ment. Observe all safety information throughout this
manual.
INVERTEC V250-S
B-2 B-2
OPERATION
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the V250-S. Refer to Figure B.1 and corre-
sponding explanations.
FIGURE B.1 � CASE FRONT CONTROLS.
4 8
SMAW SMAW
GTAW THERMAL
HOT START
SOFT CRISP
5 6
4
2 7
3
8
5
2
A
120
85
9
1
OUTPUT
3 0
170 10
50
15 ARC FORCE
230
LOCAL
REMOTE 5 6
1 4
7
3
250 8
6
2
9
1
0
10
®
INVERTEC V250-S
S
+
- I
1
O
7
1. Power Switch - Place the lever in the “ON� position to CC Soft Best for EXX18 thru EXX28 stick electrodes.
energize the machine. When the power is on, the fan will Output energized when machine is on.
operate and the output will be energized in SMAW
modes. GTAW mode requires remote trigger to energize CC Crisp Use this mode for stick welding with EXX10
the output. thru EXX14 electrodes. Output energized when machine
is on.
2. Output Control - This controls the output current. Control
is provided over the entire output range of the power 5. Hot Start - Controls the amount of starting energy in
source with 1 turn of the control knob. This control may SMAW. The Hot Start setting will set the amount of extra
be adjusted while under load to change power source power given during the initial strike.
output. When using remote control this function becomes
the limit setting. A Hot Start setting of 100% will give you an additional
striking current 100% above the welding set current*.
3. Local/Remote Switch - Place in the “LOCAL� position to (Striking current in this example will be 200% of the set
allow output adjustment at the machine. Place in the current). For a Hot Start setting of 100%, the current will
“REMOTE� position to allow output adjustment at remote decrease back to the set current in one second.
pot or amptrol. In Remote, the machine output control pot
is the limit setting for remote control. A Hot Start setting of 50% will give you an additional
striking current 50% above the welding set current*.
4. Mode Switch (Striking current in this example will be 150% of the set
GTAW Optimized for touch start use. Triggering at current). For a Hot Start setting of 50%, the current will
amphenol is required using an Arc Start Switch, Amptrol decrease back to the set current in .5 second.
or similar means. Short circuit current is limited to approx-
imately 25 amps to aid in touch starting. * The maximum striking current is 300 Amps.
INVERTEC V250-S
B-3 B-3
OPERATION
6. Arc Force - This control functions in SMAW modes CONSTANT CURRENT PROCESSES
to adjust the Arc Force. The arc is soft at the mini-
mum settings and more forceful or driving at the MANUAL ARC WELDING (STICK)
maximum settings. Higher spatter levels may be
The Invertec may be utilized as a manual DC arc
present at the maximum settings.
welder with the electrode cable, work cable, and elec-
trode holder being the only equipment required.
RECOMMENDED ARC FORCE/INDUCTANCE
SETTINGS FOR SELECTED APPLICATIONS
AIR CARBON ARC CUTTING
FULL RANGE IS 1-10. 1 is VERY SOFT, Air carbon arc cutting may be performed with the
10 IS VERY CRISP 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,
Nominal Recommended
and a source of compressed air are required.
Mode Process Setting Adjustment Range
NOTE:
CC SMAW 1 EXX18 thru 5 1 (gentle, may stick) to 9
(soft) EXX28 stick (forceful, more spatter)
1. Best performance will be at settings of 200 amps
and below.
CC SMAW 2 EXX10 thru 6 3 to 10
(crisp) EXX14 stick
2. The electronic protection circuit in the V250S will
Air Carbon Arc 1 None
Cutting
limit the current to approximately 290 amps.
7. Output Terminals - These quick disconnect termi-
TIG WELDING
nals provide connection points for the electrode and
work cables. Refer to Output Connections in the The V250S is capable of touch start TIG welding. An
Installation chapter for proper cable sizes. For electrode cable, work cable, Arc Start Switch or
positive polarity welding connect the electrode Amptrol, TIG torch, and gas supply with regulator are
cable to the positive terminal and the work cable to required. Refer to Accessories section of this manual.
the negative terminal. To weld negative polarity
reverse the electrode and work cables.
Touch starting is done as follows:
8. Thermal Shutdown Indicator - This light will illumi-
1. Place the shield cup edge on the work piece.
nate if an internal thermostat has been activated.
2. Rock the tungsten down to touch.
Machine output will return after the internal
3. Trigger the output.
components have returned to a normal operating
4. Gently rock back the tungsten from the work-
temperature. See Thermal Protection later in this
chapter. piece.
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
INVERTEC V250-S
B-4 B-4
OPERATION
PARALLEL OPERATION
The Invertec’s are operable in parallel. For best
results, the currents of each machine should be rea-
sonably 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 par-
allel will not be effective due to the voltage require-
ments of procedures in that power range.
To set machine outputs, start with output control pots
and arc force pots in identical positions. Adjust out-
puts 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 pro-
tection circuit is reset. Reset occurs when the output
load is removed.
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.
INVERTEC V250-S
C-1 C-1
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 Amptrol tm for 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.
Note: When used with the V250-S, the grounding
strap on the connector end of K963 must be discon-
nected to avoid electrical noise problems. Details are
listed under REMOTE CONTROL RECEPTACLE in
INSTALLATION section in this manual.
K870 - Foot Amptrol tm for 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.
INVERTEC V250-S
D-1 D-1
MAINTENANCE
4. Obtain a high resistance and high wattage resistor
WARNING
(25-1000 ohms and 25 watts minimum). This resis-
ELECTRIC SHOCK can kill. tor is not supplied with machine. NEVER USE A
� Have an electrician install and service SHORTING STRAP FOR THIS PROCEDURE.
this equipment.
� Turn the input power off at the fuse
5. Locate the four capacitor terminals (large hex head
box before working on equipment.
cap screws) shown in Figure D.1. One pair at the
� Do not touch electrically hot parts.
top and one pair at the bottom of the Power Board.
� Prior to Performing preventative main-
tenance, perform the following capaci-
6. Use electrically insulated gloves and insulated pli-
tor discharge procedure to avoid elec-
ers. Hold body of the resistor and connect resistor
tric shock.
leads across the two capacitor terminals. Hold
---------------------------------------------------------------------
resistor in place for 10 seconds. DO NOT TOUCH
INPUT FILTER CAPACITOR CAPACITOR TERMINALS WITH YOUR BARE
DISCHARGE PROCEDURE HANDS.
1. Turn off input power or disconnect input power 7. Repeat discharge procedure for the capacitor on
lines. other two terminals.
2. Remove the 5/16" hex head screws from the side 8. Check voltage across terminals of all capacitors
and top of the machine and remove wrap-around with a DC voltmeter. Polarity of capacitor terminals
machine cover. is marked on PC board above terminals. Voltage
should be zero. If any voltage remains, repeat this
3. Be careful not to make contact with the capacitor capacitor discharge procedure.
terminals that are located in the top and bottom of
the Power Board.
FIGURE D.1 � LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
POWER UPPER
BOARD CAPACITOR TERMINALS
LOWER
CAPACITOR
TERMINALS
POWER
RESISTOR
INSULATED
RIGHT SIDE OF MACHINE
PLIERS
INSULATED
GLOVES
INVERTEC V250-S
D-2 D-2
MAINTENANCE
ROUTINE MAINTENANCE FILTER CAPACITOR CONDITIONING
1. Perform the following preventive maintenance A protection circuit is included to monitor the voltage
procedures at least once every six months. It is across filter capacitors C1 and C2. In the event that
good practice to keep a preventive maintenance the capacitor voltage is too high, the protection circuit
record; a record tag attached to the machine will prevent output. Nominal trip setting is at 230/460
works best. VAC +15%. Reset occurs about 3% lower (230/460
VAC +12%).
2. Remove the machine wrap-around cover and per-
form the input filter capacitor discharge procedure On new installations, the protection circuit may also
(detail at the beginning of this chapter). prevent output providing all these circumstances are
met:
3. Keeping the machine clean will result in cooler
operation and higher reliability. Be sure to clean 1. Machine is connected for 380-415 or 440-460
the following areas with a low pressure air VAC input.
stream. See figure D.2 for component locations. 2. Machine did not have power applied for many
months.
� Power and control printed circuit boards 3. Machine will not produce output when power is
first switched on.
� Power switch
If these circumstances apply, the proper action is to
� Main transformer switch the machine on and let it idle for up to 30 min-
utes. This is required to condition the filter capacitors
� Input rectifier after an extended storage time. The protection circuit
will automatically reset once the capacitor conditioning
� Heat sink fins and resultant voltage levels are acceptable. It may be
necessary to turn the power switch off and back on
� Input Filter Capacitors again after this period.
� Output Terminals
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 ohm-
meter, 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.
INVERTEC V250-S
D-3 D-3
MAINTENANCE
FIGURE D.2 � LOCATION OF MAINTENANCE COMPONENTS.
INPUT RECTIFIER
CONTROL PC BOARD
POWER PC BOARD
POWER SWITCH
COOLING FANS
OUTPUT TERMINALS
OUTPUT RECTIFIER
HEATSINK FINS
MAIN TRANSFORMER
AUXILIARY TRANSFORMER
INVERTEC V250-S
E-1 E-1
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
- Remove the P.C. Board from the static-
WARNING
shielding bag and place it directly into the
ELECTRIC SHOCK can kill. equipment. Don’t set the P.C. Board on or
Have an electrician install near paper, plastic or cloth which could have
and service this equip- a static charge. If the P.C. Board can’t be
ment. Turn the input power installed immediately, put it back in the static-
OFF at the fuse box before shielding bag.
working on equipment. Do
not touch electrically hot - If the P.C. Board uses protective shorting
parts. jumpers, don’t remove them until installation
_______________________________ is complete.
CAUTION: Sometimes machine failures
appear to be due to PC board failures. These - If you return a P.C. Board to The Lincoln
problems can sometimes be traced to poor Electric Company for credit, it must be in the
electrical connections. To avoid problems static-shielding bag. This will prevent further
when troubleshooting and replacing PC damage and allow proper failure analysis.
boards, please use the following procedure:
4. Test the machine to determine if the fail-
1. Determine to the best of your technical ure symptom has been corrected by the
ability that the PC board is the most likely replacement PC board.
component causing the failure symptom.
NOTE: It is desirable to have a spare (known
2. Check for loose connections at the PC good) PC board available for PC board trou-
board to assure that the PC board is prop- bleshooting.
erly connected.
NOTE: Allow the machine to heat up so that
3. If the problem persists, replace the sus- all electrical components can reach their oper-
pect PC board using standard practices to ating temperature.
avoid static electrical damage and electri-
cal shock. Read the warning inside the 5. Remove the replacement PC board and
static resistant bag and perform the follow- substitute it with the original PC board to
ing procedures: recreate the original problem.
a. If the original problem does not reap-
P.C. Board can be dam-
pear by substituting the original
aged by static electricity.
board, then the PC board was not the
problem. Continue to look for bad
- Remove your body’s stat-
connections in the control wiring har-
ic charge before opening
ness, junction blocks, and terminal
the static-shielding bag.
ATTENTION strips.
Wear an anti-static wrist
Static-Sensitive strap. For safety, use a 1
Devices b. If the original problem is recreated by
Meg ohm resistive cord
Handle only at the substitution of the original board,
connected to a grounded
Static-Safe then the PC board was the problem.
part of the equipment
Workstations Reinstall the replacement PC board
frame.
and test the machine.
Reusable
- If you don’t have a wrist
Container 6. Always indicate that this procedure was
strap, touch an unpainted,
Do Not Destroy followed when warranty reports are to be
grounded, part of the
submitted.
equipment frame. Keep touching the frame to
prevent static build-up. Be sure not to touch
NOTE: Following this procedure and writing on the
any electrically live parts at the same time.
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,� will help avoid
- Tools which come in contact with the P.C.
denial of legitimate PC board warranty claims.
Board must be either conductive, anti-static or
static-dissipative.
INVERTEC V250-S
E-2 E-2
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage
is observed when cover wrap-around
is removed.
The machine is dead - no output - 1. The input power switch must be
no fan. in the ON position.
2. Make sure the input voltage is
correct for the machine.
3. If the machine is set for single-
phase operation, inspect to
assure that the WHITE and
BLACK leads are connected
properly and the RED lead is not
connected and is insulated. If all recommended possible areas of
misadjustment have been checked
4. Check that the input voltage set- and the problem persists, Contact
your local Lincoln Authorized Field
up switch and jumper “A� (the
reconnect auxiliary jumper) are in Service Facility.
the proper position for the input
voltage being applied. Refer to
Input Voltage Reconnect
Procedure in the Installation
Chapter.
5. Check continuity of the 0.6-amp
slow blow fuse located on the
reconnect panel.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V250-S
E-3 E-3
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
No output but the fan operates nor- 1. The mode switch must be in one
mally. of the SMAW modes or if in the
GTAW mode the remote trigger
circuit must be activated.
2. The Local/Remote switch (S3)
must be in the LOCAL position
unless a remote control device is
attached to the remote
receptacle.
3. If the machine has not been used
for a long time and is connected
for 380 VAC or higher, the
capacitors may need “condition-
ing�. See Input Filter Capacitor
Conditioning. If all recommended possible areas of
misadjustment have been checked
4. The machine may be overheated. and the problem persists, Contact
Check the thermal indicator light. your local Lincoln Authorized Field
Wait for the machine to cool and Service Facility.
the thermostats to reset.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V250-S
E-4 E-4
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Output turns on momentarily, then 1. Check the input voltages and
switches off and repeats cycle. reconnection procedures. Make
sure the input voltage is correct
for the machine. See Input
Voltage Reconnect Procedure.
2. Check or replace remote control
device. (If used)
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
Remote output control not 1. Make sure the Local/Remote
functioning. The machine operates switch (S3) is in the REMOTE
normally on LOCAL control. position.
2. The remote control device may
be faulty. Replace.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V250-S
E-5 E-5
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
No output - Main input fuses open, 1. Inspect input leads for possible
indicating excessive current draw. shorts or grounds or mis-connec-
tions.
2. Install new fuses and reapply
power. If fuses open again, con-
sult a Lincoln Authorized Field
Service Facility.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
1. Check the input voltage and input Service Facility.
The machine operates normally
when connected for 200 - 230VAC voltage reconnect procedures.
input. There is no output when the See Installation Section of this
machine is connected to 380VAC or manual.
higher.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V250-S
E-6 E-6
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
The machine will not produce more 1. This may be normal operation. If
than 200 amps. the output current exceeds 290
amps, an electronic protection
circuit will reduce the current to
less than 200 amps. The
machine will continue to produce
this low current until the
If all recommended possible areas of
protection circuit is reset. Reset
misadjustment have been checked
occurs when the output load is
and the problem persists, Contact
removed.
your local Lincoln Authorized Field
Service Facility.
2. Check the input voltage and input
voltage reconnect procedures.
See Input Voltage Reconnect
Procedure.
3. Check for loose or faulty welding
cables.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V250-S
E-7 E-7
TROUBLESHOOTING & REPAIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Poor welding, weld settings drift, or 1. Make sure the machine settings
output power is low. are correct for the weld process
being used.
2. Check machine performance on
LOCAL control. If OK then the
remote control device may be
faulty. Check or replace.
3. Check the input voltages and
input voltage reconnect
procedures. See Installation
Section of this manual.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
Poor stick electrode welding 1. Check for loose or faulty welding
performance. The arc pops out. cables.
2. Is the electrode DRY? Try weld-
ing with another electrode from a
different container. Make sure
you have the correct electrode for
the application.
3. Make sure the machine settings
are correct for the weld process
being used.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V250-S
WIRING DIAGRAM - INVERTEC V250-S
F-1
L2 RIGHT
D8
S F C4
R2
10
F
204 2W
.001/400
F BACK
+ ARC
BACK
AUX.
206 OUTSIDE C5
TP5
S
S
+
N.C. 229
204 S F
206
C1 204 FRONT TP6
1600/450 BACK
I INSIDE D5, D6, D7
- F S
F
S4 202
206 201 TP4
201 C6
203A
201
PRIMARY 203A
203A F
207
RECONNECT
203
SWITCH 202A 205 205 - ARC
203 POWER S
F
205
202 315 BW
I
BOARD FRONT
Y Y
202A FRONT 316
OUTSIDE 2 CC SOFT
S F 304
S2
T3
+
1
303
S
CURRENT MODE
CC GTAW
2
202A W
W§ 31/32
S 1
309AA6Å’qb
C2 BACK
S1 303A
J4
FRONT D2, D3, D4
TRANSFORMER SWITCH
207 1
INSIDE B
310 6
1600/450
POWER AUX. 305
.001/400 CC CRISP
307
- 7
F 3
ON
OFF 10
F
208
207A 208 R1 4
308 375
2W 1
W 208
207A
A J2
F C3
U F
S 2
H1 311 2 377 303A S3
TP1 H1 REMOTE
1 313
308 8 3
D9 324
D1
-
330 LOCAL/REMOTE
L1 LEFT
307
2 3
Y LOCAL
INPUT 4 376
R SWITCH
B
INPUT 310
V 3 T1 Y 5
BRIDGE 330
5
J6
PER TP2 TP3 4 MAIN
311 6 321
N.A.
CW (MAX)
377
TRANSFORMER
5 313
209
B 303
D 7 R3
C J3
316 2
6 309
W 209
A 305
8 OUTPUT
10K
R3
376
4
317
+
9 304 CONTROL
2W
G J1
R 3 10 327
375
1
R
328
11
375B
229
12
FAN CONTROL 319
A 13 327 CW (MAX)
R4
MOTORS BOARD
H1 14
0.6 AMP ARC FORCE
10K
J5
R4
SLOW 328
315 /INDUCTANCE
2W
H3
BLOW
CONTROL
317 425
1
WIRING DIAGRAM- CODES: 10102, 10103
6 3
A
J7 R6
H1
1
H1 324 CW (MAX)
100
R5
5W 322 318 75 76 77
R R R R STRIKE ENERGY
50K
R5
H2
CONTROL
H2 4 2W
200-
R
208V H3
375B
H3 18V
2
H3
220-
R
230V
H4
3
H4
DIAGRAMS
INVERTEC V250-S
380-
415V
H5
6
A H5
440-
5
460V T2
J2
J5, J6, J7
J1
J4
N.C. J3 +
321
AUXILIARY
THERMAL
TRANSFORMER
OVERLOAD
Y
INDICATOR
NOTES:
N.A. 319
1. FOR MACHINES SUPPLIED WITH INPUT CABLE
CONNECTOR CAVITY NUMBERING SEQUENCE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
(VIEWED FROM COMPONENT SIDE OF BOARD)
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. 322 D GTAW (REMOTE)
2
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
E
318 TRIGGER
4
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. MIN
75 C 75
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE
REMOTE
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
OUTPUT
76
76 B
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. COLOR CODE: CONTROL
A 77
77
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. B = BLACK
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. G = GREEN
F
G GND
R = RED
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
W = WHITE
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
Y = YELLOW
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
REMOTE
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONTROL
CONNECTION SHOWN IS FOR 440-460V OPERATION. RECEPTACLE
N.D. D2 THRU D4 OUTPUT DIODES ARE A MATCHED SET.
D5 THRU D7 OUTPUT DIODES ARE A MATCHED SET.
N.E. C1, C2 CAPACITORS ARE A MATCHED SET.
ELECTRICAL SYMBOLS PER E1537
8-5-94
L9280
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted
F-1
inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
WIRING DIAGRAM - INVERTEC V250-S
F-2
L2 RIGHT
D1A
S F
10
F
204 2W
F BACK
+ ARC
BACK
AUX.
206 OUTSIDE C5
TP5
S
S
+
N.C. 229
204 S F
206 D2B
C1 204 FRONT TP6
1600/450 BACK
I INSIDE
- F S
F
S4 202
206 201 TP4
201 C6
203A
201
PRIMARY 203A
203A F
207
RECONNECT
203
SHUNT
SWITCH 202A 205 205 - ARC
203 POWER S
F
205
202 317 BW
I
BOARD FRONT
Y Y
202A FRONT 320
OUTSIDE 2 CC SOFT
S F 304
S2
T3
+
1
D2A 303
S
CURRENT MODE
CC GTAW
2
202A W
S 1
309
C2 BACK
S1 303A
J4
FRONT
TRANSFORMER SWITCH
207 1
INSIDE B
310 6 }
1600/450
POWER AUX. 305
CC CRISP
307
- 7
F 3
ON
OFF 10
F
208
207A 208 4
308 375
2W 1
W 208
207A
A J2
F
U F
S 2
H1 311 2 377 303A S3
TP1 H1 REMOTE
1 313
308 8 3
D9 324
D1B
-
330 LOCAL/REMOTE
L1 LEFT
307
2 3
Y LOCAL
INPUT 4 376
R SWITCH
B 320
INPUT 310
V 3 T1 Y
}
5
BRIDGE 330
5
OUTPUT
J6
PER TP2 TP3 4 MAIN
311 6 321
RECTIFIER
N.A.
CW (MAX)
377
TRANSFORMER
5 313
}
209 HEATSINK
B 303
D 7 R3
C
} J3
316 2
6 309
W 209
A 305
8 OUTPUT
10K
318
R3
376
4
317
+
9 304 CONTROL
2W
G J1
R 3 10
318 327
} 375
1
R
POWER BOARD 328
11
375B
229
12
HEATSINK
FAN CONTROL 319
A 13 327 CW (MAX)
316 R4
MOTORS
}
BOARD
H1 14
0.6 AMP ARC FORCE
10K
J5
R4
SLOW 328 /INDUCTANCE
2W
H3
BLOW
}
CONTROL
425
1 6 3
A
WIRING DIAGRAM- CODES: 10187, 10188
J7
H1
1
H1 324 CW (MAX)
R5
322 318 75 76 77 STRIKE ENERGY
50K
R5
H2
CONTROL
H2 4 2W
200-
R
208V H3
375B
H3 18V
2
H3
220-
R
230V
H4
3
H4
DIAGRAMS
INVERTEC V250-S
380-
415V
H5
6
A H5
440-
5
460V T2
J2
J5, J6, J7
J1
J4
N.C. J3 +
321
AUXILIARY
THERMAL
TRANSFORMER
OVERLOAD
Y
INDICATOR
NOTES:
319
N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE
CONNECTOR CAVITY NUMBERING SEQUENCE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
(VIEWED FROM COMPONENT SIDE OF BOARD)
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. 322 D GTAW (REMOTE)
2
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
E
318 TRIGGER
4
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. MIN
75 C 75
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE
REMOTE
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
OUTPUT
76
76 B
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT. COLOR CODE: CONTROL
A 77
77
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES. B = BLACK
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. G = GREEN
F
G GND
R = RED
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
W = WHITE
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
}
Y = YELLOW
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
REMOTE
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONTROL
CONNECTION SHOWN IS FOR 440-460V OPERATION. RECEPTACLE
N.D. D2 THRU D4 OUTPUT DIODES ARE A MATCHED SET.
D5 THRU D7 OUTPUT DIODES ARE A MATCHED SET.
N.E. C1, C2 CAPACITORS ARE A MATCHED SET.
ELECTRICAL SYMBOLS PER E1537
9-29-95E
L9907
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-2
WIRING DIAGRAM - INVERTEC V250-S (CE)
F-3
L2 RIGHT
D1A
S F
10
F
204 2W
F BACK
+ ARC
BACK
AUX.
206 OUTSIDE S
S
+
N.C. BYPASS 229
204 S F
206 D2B
C1 204 BOARD
FRONT
1600/450 BACK
I INSIDE
- F S
F
S4 202
206 201 201
203A
201
PRIMARY 203A
203A F
207
RECONNECT
203
SHUNT
SWITCH 202A 205 205 - ARC
203 POWER S
F
205
202 317 BW
I
BOARD FRONT
Y Y
202A FRONT 320
OUTSIDE 2 CC SOFT
S F 304
S2
T3
+
1
D2A 303
S
CURRENT MODE
CC GTAW
2
202A W
+W § AA6Œqb 31/32
S 1
309
C2 BACK
S1 303A
POWER LINE J4
FRONT
TRANSFORMER SWITCH
207 1
INSIDE B
310 6
1600/450
POWER AUX. 305
FILTER
CC CRISP
307
- 7
F 3
ON
OFF 10
F
208
207A
A 208
A1 4
308 375
2W 1
W 208
207A
A J2
F
U F
S 2
H1 311 2 377
TP1 303A S3
H1 REMOTE
D9 1 313
308 8 3 324
D1B
-
330 LOCAL/REMOTE
B1 L1 LEFT
B 307
INPUT 2 3
Y LOCAL
4 376
R SWITCH
B
LINE
320
INPUT
LOAD
BRIDGE 310
V 3 T1 Y 5 330
5
TP2 OUTPUT
J6
PER
4 MAIN
311 6 321
TP3 RECTIFIER
N.A.,
CW (MAX)
377
C TRANSFORMER
5 313
209 HEATSINK
B 303
D 7 R3
N.F. C J3
316 2
6 309
W 209
A 305
8 OUTPUT
C1 10K
318
R3
376
4
317
+
WIRING DIAGRAM- CODE: 10304
9 304 CONTROL
2W
G J1
R 3 10
318 327
375
1
R
N.F.
POWER BOARD 328
11
375B
229
12
HEATSINK
FAN CONTROL 319
A 13 327 CW (MAX)
316 R4
MOTORS BOARD
H1
0.6 AMP 14
ARC FORCE
10K
J5
SLOW
R4
328 /INDUCTANCE
2W
H3
BLOW
CONTROL
425
1 6 3
A
J7
H1
1
H1 324 CW (MAX)
R5
322 318 75 76 77 STRIKE ENERGY
50K
R5
H2
CONTROL
H2 4 2W
200-
R
208V H3
375B
H3 18V
2
H3
220-
R
230V
J2
J5, J6, J7
J1
J4 J3
H4
BASE 3
FRONT CENTER H4
380-
INVERTEC V250-S
LEFT SIDE COLOR CODE:
PANEL PANEL
415V
B = BLACK
H5
6
A G = GREEN
H5
PROTECTIVE BONDING CIRCUIT
440-
R = RED
5
460V T2 W = WHITE
N.C. +
CONNECTOR CAVITY NUMBERING SEQUENCE 321
Y = YELLOW
AUXILIARY
THERMAL
(VIEWED FROM COMPONENT SIDE OF BOARD)
TRANSFORMER
OVERLOAD
Y
INDICATOR
NOTES:
319
ELECTRICAL DIAGRAMS
N.A. 1. FOR MACHINES SUPPLIED WITH INPUT CABLE
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK & WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. 322 D GTAW (REMOTE)
2
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
E
318 TRIGGER
4
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT. MIN
75 C 75
2. FOR MACHINES NOT SUPPLIED WITH INPUT CABLE
REMOTE
FOR SINGLE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
OUTPUT
76
76 B
CONNECT TERMINALS U & W TO SUPPLY CIRCUIT.
CONTROL
A 77
77
FOR THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT.
F
G GND
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT
AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW
THE EXACT COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
REMOTE
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE. CONTROL
CONNECTION SHOWN IS FOR 440-460V OPERATION. RECEPTACLE
N.D. D2 THRU D4 OUTPUT DIODES ARE A MATCHED SET.
D5 THRU D7 OUTPUT DIODES ARE A MATCHED SET.
N.E. C1, C2 CAPACITORS ARE A MATCHED SET.
ELECTRICAL SYMBOLS PER E1537
N.F. ROUTE LINES THROUGH POWER LINE NOISE SHIELD.
12-19-97
L9907-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-3
WIRING DIAGRAM - INVERTEC V250-S 380-415V
F-4
L2 RIGHT
D1A
S F
10
F
204 2W
F BACK
+ ARC
BACK
AUX.
OUTSIDE S C5
TP5
S
+
229
204 S TP6
F
206 D2B
C1 204 FRONT
1600/450 BACK
I INSIDE
C6
- F TP4
S
F
201 201
203A
201
F
SHUNT THERMOSTAT SHUNT
205 205 - ARC
POWER S
F
205 317 BW
I
BOARD FRONT
Y Y
FRONT 320
OUTSIDE 2 CC SOFT
S F 304
S2
T3
+
1
D2A 303
S
CURRENT MODE
CC GTAW
2
202A W
S1 +W § AA6Œqb 31/32
S 1
309
C2 BACK 303A
J4
FRONT
TRANSFORMER SWITCH
1
INSIDE B
310 6
POWER 1600/450 AUX. 305
CC CRISP
307
- 7
F 3
ON
OFF 10
F
208
207A 208 4
308 375
2W 1
208
207A
C J2
F
U F
S 2
311 2 377
T1
TP1 303A S3
REMOTE
D9 1 313
308 8 3 324
D1B
MAIN
-
330 LOCAL/REMOTE
H4A L1 LEFT
307
INPUT 2 3
Y LOCAL
4
TRANSFORMER 376 SWITCH
B
INPUT 320
BRIDGE 310
V 3 Y 5 330
5
TP2
PER J6
4 311 6
TP3 321
OUTPUT
N.A.
CW (MAX)
377
5 313
209 RECTIFIER 303
D 7 R3
A J3
316 2
6 309
W H1 209 HEATSINK 305
8 OUTPUT
10K
318
R3
H1 376
4
317
THERMOSTAT
+
WIRING DIAGRAM- CODE: 10467
9 304 CONTROL
2W
J1
R 3 10
318 327
REAR 375
1
R
POWER BOARD
328
11
TERMINAL 375B
HEATSINK
229
12
THERMOSTAT
FAN CONTROL 319
H4A 13 327 CW (MAX)
316 R4
MOTORS BOARD
H1
0.6 AMP 14
ARC FORCE
10K
J5
SLOW
R4
328
CONTROL
2W
H3
BLOW
425
1 6 3
H4
SIDE J7
H1
TERMINAL
1
H1 324 CW (MAX)
0V R5
322 318 75 76 77 HOT START
50K
R5
H2
CONTROL
4 2W
R
375B
H3 18V
2
H3
220V R
H4
3
H4
INVERTEC V250-S
400V
H5
6
J2
J5, J6, J7
J1
5 J4 J3
T2
+
321
COLOR CODE:
AUXILIARY
THERMAL
B = BLACK
TRANSFORMER
OVERLOAD
Y
G = GREEN
INDICATOR
R = RED
W = WHITE 319
CONNECTOR CAVITY NUMBERING SEQUENCE
Y = YELLOW
ELECTRICAL DIAGRAMS
(VIEWED FROM COMPONENT SIDE OF BOARD)
322 D GTAW (REMOTE)
2
NOTES:
E
318 TRIGGER
4
MIN
75 C 75
THREE PHASE INPUT: GROUND MACHINE PER NATIONAL AND LOCAL ELECTRICAL CODES.
N.A. REMOTE
OUTPUT
CONNECT TERMINALS U, V & W TO SUPPLY CIRCUIT. 76
76 B
CONTROL
A 77
77
F
G GND
REMOTE
CONTROL
RECEPTACLE
ELECTRICAL SYMBOLS PER E1537
9-19-97
L9907-2
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-4
DIMENSION PRINT
F-5
15.04
12.58
DIAGRAMS
INVERTEC V250-S
9.13
19.72
M17229
8-5-94
F-5
NOTES
INVERTEC V250-S
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187 pages with more than 100 illustrations. Size 8-1/2� x 11� Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
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USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
BOOKS OR FREE INFORMATIVE CATALOGS
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition� $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 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
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