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Lincoln Electric IM490-C manual

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Table of contents for the manual

  • Page 1

    INVERTEC V250-S OPERA TOR’S MANUAL IM490-C February, 2001 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[...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS 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[...]

  • Page 4

    FOR ELECTRICALL Y 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 C[...]

  • Page 5

    iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

  • Page 6

    INVERTEC V250-S Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick re[...]

  • Page 7

    INVERTEC V250-S vi T ABLE OF CONTENTS PAGE INSTALLATION ................................................................................................................... ....SECTION A TECHNICAL SPECIFICATIONS ........................................................................................A-1 & A-2 SAFETY PRECAUTIONS ..................[...]

  • Page 8

    A-1 INST ALLA TION INVERTEC V250-S A-1 Height Width Depth Weight 15.0 in. 9.1 in. 19.7 in. 36 lbs. 381 mm 231 mm 500 mm 17 Kg PHYSICAL DIMENSIONS THREE PHASE SINGLE PHASE Standard Input Current Voltage at Rated Output Model 208/230/460 60Hz 34/32/16 60Hz 200/220/400/440 50/60Hz 35/33/18/17 50/60 Hz 380-415 50Hz 20/18 50Hz Volts at Duty Cycle (1) Am[...]

  • Page 9

    A-2 INST ALLA TION INVERTEC V250-S A-2 Height Width Depth Weight 15.0 in. 9.1 in. 19.7 in. 41 lbs. 381 mm 231 mm 500 mm 19 Kg PHYSICAL DIMENSIONS THREE PHASE SINGLE PHASE Standard Input Current Voltage at Rated Output Model 220/440 35% Duty Cycle 34/17 50/60 Hz 400 60% Duty Cycle 16 50/60 Hz 220/400/440 100% Duty Cycle 19/11/9 50/60 Hz Volts at Dut[...]

  • Page 10

    A-3 INST ALLA TION INVERTEC V250-S A-3 Read this entire installation section before you start installation. SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Have an electrician install and ser- vice this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • Be sure to disch[...]

  • Page 11

    A-4 INST ALLA TION INVERTEC V250-S A-4 POWER INPUT CONNECTION FOR 50/60 HZ MACHINES 1. Connect terminal marked to earth ground per National Electric Code. 2. Connect the supply lines to the line switch. Torque to 3.0 Nm. 3 . Install in accordance with all local and national electric codes. The Invertec V250-S machine is supplied with one cord conne[...]

  • Page 12

    A-5 INST ALLA TION INVERTEC V250-S A-5 OUTPUT CONNECTIONS Refer to figure A.2 for the location of the 6 Pin Remote Receptacle and the Output Terminals. FIGURE A.2 OUTPUT CONNECTIONS REMO TE CONTR OL RECEPT A CLE Remote control (K857), Arc start switch (K814), Hand amptrol (K963) and Foot amptrol (K870) connect directly to 6 pin amphenol on the fron[...]

  • Page 13

    B-1 OPERA TION B-1 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). OPERA TIONAL FEA TURES The Invertec V250-S provides continuous total range out[...]

  • Page 14

    B-2 OPERA TION B-2 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[...]

  • Page 15

    B-3 OPERA TION B-3 6. Arc Force - This control functions in SMAW modes to adjust the Arc Force. The arc is soft at the mini- mum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings. 7. Output Terminals - These quick disconnect termi- nals provide connection points for the elect[...]

  • Page 16

    B-4 OPERA TION B-4 P ARALLEL OPERA TION 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[...]

  • Page 17

    C-1 A CCESSORIES C-1 OPTIONS / A CCESSORIES 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. REMO TE CONTR OLS K857 - Remote Output Control for stick welding. K963 - Hand Amptro[...]

  • Page 18

    D-1 MAINTENANCE D-1 INPUT FIL TER CAP A CIT OR DISCHARGE PR OCEDURE 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[...]

  • Page 19

    D-2 MAINTENANCE D-2 R OUTINE 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 per- form the input filter capacitor discharge procedure (detai[...]

  • Page 20

    D-3 MAINTENANCE D-3 INVERTEC V250-S FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. POWER PC BOARD CONTROL PC BOARD INPUT RECTIFIER OUTPUT RECTIFIER HEA TSINK FINS MAIN TRANSFORMER OUTPUT TERMINALS POWER SWITCH COOLING F ANS AUXILIARY TRANSFORMER[...]

  • Page 21

    INVERTEC V250-S E-1 TR OUBLESHOO TING & REP AIR E-1 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: 1 . Determine to[...]

  • Page 22

    E-2 TR OUBLESHOO TING & REP AIR E-2 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION Major physical or electrical damage is observed when cover wrap-around is removed. The machine is dead - no output - no fan. 1. Th[...]

  • Page 23

    E-3 TR OUBLESHOO TING & REP AIR E-3 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION No output but the fan operates nor- mally. 1. The mode switch must be in one of the SMAW modes or if in the GTAW mode the remote t[...]

  • Page 24

    E-4 TR OUBLESHOO TING & REP AIR E-4 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION Output turns on momentarily, then switches off and repeats cycle. Remote output control not functioning. The machine operates norm[...]

  • Page 25

    E-5 TR OUBLESHOO TING & REP AIR E-5 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION No output - Main input fuses open, indicating excessive current draw. The machine operates normally when connected for 200 - 230VA[...]

  • Page 26

    E-6 TR OUBLESHOO TING & REP AIR E-6 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION The machine will not produce more than 200 amps. 1. This may be normal operation. If the output current exceeds 290 amps, an elect[...]

  • Page 27

    E-7 TR OUBLESHOO TING & REP AIR E-7 INVERTEC V250-S Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPT OMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF A CTION Poor welding, weld settings drift, or output power is low. Poor stick electrode welding performance. The arc pops out. 1. Make su[...]

  • Page 28

    F-1 DIA GRAMS F-1 INVERTEC V250-S ELECTRICAL SYMBOLS PER E1537  W § AA6Œqb 31/32 H1 18V 76 C B A F 75 76 77 GND REMOTE CONTROL RECEPTACLE MIN T3 T2 OFF ON H1 I I TP5 B W TP4 C6 C5 311 313 W B 376 330 303 327 304 303 303A 305 1 2 3 377 376 330 303A LOCAL REMOTE 327 328 J4 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOA[...]

  • Page 29

    F-2 DIA GRAMS F-2 INVERTEC V250-S ELECTRICAL SYMBOLS PER E1537 H1 18V 76 C B A F 75 76 77 GND REMOTE CONTROL RECEPTACLE MIN T3 T2 OFF ON H1 I I TP5 B W TP4 C6 C5 311 313 W B 376 330 303 327 304 303 303A 305 1 2 3 377 376 330 303A LOCAL REMOTE 327 328 J4 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) NOTES: REMOTE OUTPUT C[...]

  • Page 30

    F-3 ELECTRICAL DIA GRAMS F-3 INVERTEC V250-S ELECTRICAL SYMBOLS PER E1537 +W  § AA6Œqb 31/32 H1 18V 76 C B A F 75 76 77 GND REMOTE CONTROL RECEPTACLE MIN T3 T2 OFF ON H1 I I B W 311 313 W B 376 330 303 327 304 303 303A 305 1 2 3 377 376 330 303A LOCAL REMOTE 327 328 J4 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) N[...]

  • Page 31

    F-4 ELECTRICAL DIA GRAMS F-4 INVERTEC V250-S ELECTRICAL SYMBOLS PER E1537 +W  § AA6Œqb 31/32 H1 18V 76 C B A F 75 76 77 GND REMOTE CONTROL RECEPTACLE MIN T3 T2 OFF ON H1 I I B W 311 313 W B 376 330 303 327 304 303 303A 305 1 2 3 377 376 330 303A LOCAL REMOTE 327 328 J4 CONNECTOR CAVITY NUMBERING SEQUENCE (VIEWED FROM COMPONENT SIDE OF BOARD) N[...]

  • Page 32

    F-5 DIA GRAMS F-5 INVERTEC V250-S 19.72 15.04 12.58 9.13 DIMENSION PRINT M17229 8-5-94[...]

  • Page 33

    NO TES INVERTEC V250-S[...]

  • Page 34

    Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. This printing will go fast so don ’ t delay. Place your order now using the coupon below. The hardbound book con[...]

  • Page 35

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA [...]

  • Page 36

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

  • Page 37

    • 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 • World's Leader in Welding and Cutting Products •[...]