Lincoln Electric V250-S User's Manual
Contents
1. A SYOLOW 91 HNIS1VAH dHVOS HAMOd 81 NISL V3H In E A 8 gt 1062 5 026 8 gt 616 4 Zap Y 2 80 4 gt 10 9 01 133111 H3 HOJSNVH NIVIN LL 3015110 I 6 6 816 ELE lt 5 lt ic p 206 808 el 802 Ae K IS T 08 0091 H3 106 ON ON MEI 200 5 2 900 S OSZA O3 LU3ANI SNIHIA HOLIMS 193NNOO3H AuVWIdd 75 N VON INVERTEC V250 S LINCOLN E F 3 Jequunu epoo 1ueuudinbe e 104 jueundedeg eorues 0 914 9 s eui j sjeued y jo euo uo eui episui pejsed si e Jenueui siy Aq JO eq jou Aew S SIUL 310 20661 CISIHS 3SION H3MOd HONOHHL S3NET31008 LAS Q3HO1VM v 20 19 138 Q3HOLVNW V 530010 1Nd1NO Za NYHL 90 IAS 38V 530010 1Nd1NO NYHL NOILVH3dO 099 077 SI NMOHS NOLLO3NNOO LNdNI 803 NOLLO3NNOO 31VIHdOHddY NO ONT 30V 1d HAgNNN 3009 NOWINOO V 9NIAVH2. 209 sr Ir 5 lt 5 Le 08 9 9 m 9 806 mo 108 zt GE N MEL joi Be 9282 XW MO LE 17201 MYLO 00 4j AC o 1208 90 T 2 31038 VE0 61e d et 622 el 86 q 1L 1 01 708 K 6 soe 8 08 0 LGE 4 9 mee S 9 6 v D 16 2 gle d quvoa 10 1 00 SYOLOW La ANISONBIHL Nui 7 806 4 1 108 1 9 b 0i 4 1VISONH3HL MNISLV3H 43111934 ui HBNHOJSNVUL 3GISNI ova 3015100 102 3GISNI 3015110 702 60 4 9 sle qe 5 LLE 018 Q 6 108 806 lt goz E U3AHOJSNVHL 1 399109 EL 900 902 AC 00 700 YNISLYIH HAMOd 1 i 09 009 02 29 Quvog VE0e 1 09 009 goz 17 9 086 S 0SCA DALYAANI l inant 8 60 7 MIEL 3015 TWNIWEBLL 9310 INVERTEC V250 S LINCOLN E 5 DIMENSION PRINT DIAGRAM 19 72 15 04 12 58 INVERTEC V250 S LINCOLN F 5 M17229 8 5 94 5 INVERTEC V250 S LINCOLN 8 Now Available 12th Edition The Procedure Handbook of Arc Welding Wi
3. au j sjeued y jo euo uo eui episul pejsed si e siy Aq je eq jou Aew Ajuo eouoJojeJ SI SIUL 310 10661 46513 ddd 5108 5 1V91419313 138 GHHOLYN 38V SHOLIOVdVO 20 19 FN DIAGRAMS 10187 10188 F 2 WIRING DIAGRAM CODES OHLNO9 109110 EIER 4399141 v GLOWY 19 2 YOLVOIGNI QvO 83AO WER 71081 00 AOU3N3 Su JOHLINOO SONVLONGNI 30404 OH1NOO d HOLIMS 3LON34 1V907 Z 65 319V1d3934 10 1 002 31038 m pu Des ef 92778 gt 9L S439 gt GL NN 5 gig 0 gt 066 XOS OL MO cy lt lt wot AE 1 201 o gt 06 C 57 de 4 HOLIMS 3dOW AS 9 QN9 4 9 OD MOTIJA 3009 80109 40 3015 1N3NOdWOO WOHA 39N3N03S ONIH3SIATN ALIAVO HOLOANNOO 8 8555 65 ES tE oo joo ES DES E T 21 er La dp nm LAS GSHOLWW v 38v 530010 1Nd1NO 28 NYHL LAS GAHOLVW V 530014 104100 vA ZA 097 077 S
4. WARNING ELECTRIC SHOCK can kill e Have an electrician install and service this equip ment Turn the input power OFF at the fuse box before working on equipment Do not touch electrically hot parts 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 the best of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is prop erly connected 3 If the problem persists replace the sus pect PC board using standard practices to avoid static electrical damage and electri cal shock Read the warning inside the static resistant bag and perform the follow ing procedures P C Board can be dam aged by static electricity Remove your body s stat ic charge before opening the static shielding bag Wear an anti static wrist strap For safety use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame Aya ATTENTION Static Sensitive Devices Handle only at Static Safe Workstations Reusable Container Do Not Destroy If you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent sta
5. 7 Replace machine cover and screws FILTER CAPACITOR CONDITIONING A protection circuit is included to monitor the voltage across filter capacitors C1 and C2 In the event that the capacitor voltage is too high the protection circuit will prevent output Nominal trip setting is at 230 460 VAC 15 Reset occurs about 3 lower 230 460 VAC 12 On new installations the protection circuit may also prevent output providing all these circumstances are met 1 Machine is connected for 380 415 or 440 460 VAC input 2 Machine did not have power applied for many months 3 Machine will not produce output when power is first switched on If these circumstances apply the proper action is to switch the machine on and let it idle for up to 30 min utes This is required to condition the filter capacitors after an extended storage time The protection circuit will automatically reset once the capacitor conditioning and resultant voltage levels are acceptable It may be necessary to turn the power switch off and back on again after this period INVERTEC V250 S LINCOLN 8 D 3 MAINTENANCE D 3 FIGURE D 2 LOCATION OF MAINTENANCE COMPONENTS INPUT RECTIFIER CONTROL PC BOARD POWER PC BOARD POWER SWITCH OUTPUT TERMINALS OUTPUT RECTIFIER HEATSINK FINS MAIN TRANSFORMER AUXILIARY TRANSFORMER INVERTEC V250 S LINCOLN 8 1 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES
6. Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 i SAFETY i PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi b
7. Quantity Cost ct _ 5450 Le eu mn WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese BIR Korean Do nottouch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra o REPORTA XuiiHMIIC MLMPT APSSAPRBS NTUSHIELTFSU e SR TERRAE ER ER 945 MIER d TH ecran SSE RE S c sup nile e AXE HZA ole AMI W o e uil el all oa Ye Si eani das ag ENT gh la uae ell DUA dan Vile Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos cosiT
8. 5 gt 26 4 GIE N 3009 40100 duvog 40 3415 LNJNOdWOO 035 9NIH38WAN ALIAVO HOLO3NNOO sm 2 6252 HH 2222 HR b i Cat 1 er Ar or sr Ve LAS Q3HO1VMW v SHOLIOVdVO 20 10 F N 7145 SHV 530010 1Nd1NO 20 NYHL LAS GSHOLVW v 530010 104100 ON NOILVH3dO HOS SI NMOHS NOILOANNOO LAANI NOLLO3NNOO 11VIHdOHddY NO QV31 49V1d O N 3309 NOWIAOO V ONIAVH AHLINOHI9 HO SLNANOdWOO LOVX3 3HL MOHS LON AVIN Wei EW Qu vog 31314NOO V 30 ALLTISV3ONVHOH3LNI JHL 123 4 LNOHLIM 39NVHO AVIA LIN9H19 Q31NIHd V 40 AHLINOHI9 HO SIN3NOdWOO JONIS LINOHI9 ATddNS OL M A N STVNIAU3L L93NNOO 7530092 1 21 19413 17901 VNOLLVN H3d 3NIHOVIN L dNI 3SVHd 338H1 803 Add AS OLM SIYNINHAL LOSNNOO S3009 1V91419413 1 201 ON TWNOILYN Yad 3NIHOVIA GNNOYD UM 3SVHd TTONIS 318VO LION HLIM 03119915 LON S3NIHOVIN HO Add NS OL SQv31 79 18 LO3NNOO 3009 91419714 IVNOLLVN H3d OL QV3 1 N33H9 LOANNOO UNI 3SVHd 338HL NOILVINSNI 71009 OL Qv3 1 AlddNS 0150 1009 91419373 H3d GNNOH9 OL N3389 LOANNOO LNdNI SSVHd TTONIS 31870 LAdNI HLIM 5 S3NIHO
9. 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 eee 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 amp Number Code amp 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 A 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 V
10. REMOTE CONTROLS K857 Remote Output Control for stick welding K963 Hand Amptrol 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 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 LINCOLN 8 D 1 ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse 5 box before working on equipment Do not touch electrically hot parts Prior to Performing preventative main tenance perform the following capaci h tor discharge procedure to avoid elec 6 tric shock INPUT FILTER CAPACITOR DISCHARGE PROCEDURE 1 Turn off input power or disconnect input power 7
11. o o Lo THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 521230 Figure Input Voltage Reconnect Instructions INVERTEC V250 S LINCOLN 8 A 5 INSTALLATION A 5 OUTPUT CONNECTIONS Refer to figure A 2 for the location of the 6 Pin Remote Receptacle and the Output Terminals FIGURE A 2 OUTPUT CONNECTIONS Le 9 y e 120 8 6 PIN os 85 NU REMOTE 50 Yo RECEPTACLE 2 WS x im 250 QS 5 9 Log UM L OUTPUT TERMINALS REMOTE CONTROL RECEPTACLE Remote control K857 Arc start switch K814 Hand amptrol K963 and Foot amptrol K870 connect directly to 6 pin amphenol on the front of the unit Note A minor modification is needed when K963 Hand Amptrol is used with the V250 S The braided grounding strap must be disconnected from connector body on end of cable that attaches to machine Remove cable clamp screw securing grounding strap remove strap and reinstall screw Run grounding strap along side of cable so that it does not contact connector body and secure in place with electrical tape This modification is necessary in order to avoid coupling electrical noise from the case of the machine onto the control leads which would otherwise result in poor starting and unstable welding performance OUTPUT CABLES Select the output cable size based on Table A 1 TABLE A 1
12. use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your
13. 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place
14. CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 440 460 380 415v 8 220 230V a 200 208V ELECTRIC SHOCK use or service this equipment INPUT VOLTAGE RECONNECT PROCEDURE When received directly from the factory units are con nected for the highest input voltage 440 VAC for 50 60 Hz machines and 460 VAC for 60 Hz machines If 440 or 460 is the desired input then the machine may be connected to the power system with out any setup required inside the reconnect door However verify the connection with the following pro cedure For other voltages refer to the instructions located on the Reconnect Panel Access Door or fol low the instructions below CAUTION Failure to follow these instructions can cause immedi ate failure of components within the welder 1 Open the access door on the right side of the machine 2 For 200 230 Position the large switch to 200 230 For 380 460 Position the large switch to 380 460 3 Move the A lead to the appropriate terminal Refer to figure A 1 below AA WARNING Disconnect input power before inspecting or servicing machine Do not operate with wraparound removed Do not touch electrically live parts Only qualified persons should install IF MACHINE CEASES TO OPERATE NO METER NO FAN AND THERE IS NO OTHER KNOWN FAILURE CHECK FUSE REPLACE WITH SPECIFIED FUSE 3 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE
15. Cable Sizes for Combined Length of Electrode and Work Cable Copper Cable Rated at 75 C Cable Size up to 150 ft 46m 1 0 50mm up to 250 ft 72m 2 0 70mm QUICK DISCONNECT PLUGS A quick disconnect system is used for the welding cable connections The welding plug included with the machine is designed to accept a welding cable size of 1 0 to 2 0 1 Remove 1 in 25mm of welding cable insulation 2 Slide rubber boot onto cable end The boot end may be trimmed to match the cable diameter Soap or other lubricant will help to slide the boot over the cable WELDING CABLE 3 Slide the copper tube into the brass plug 4 Insert cable into copper tube 5 Tighten set screw to collapse copper tube Screw must apply pressure against welding cable The top of the set screw will be well below the surface of the brass plug after tightening Jo SCREW Ki BRASS PLUG COPPER TUBE 6 Slide rubber boot over brass plug The rubber boot must be positioned to completely cover all electrical surfaces after the plug is locked into the receptacle INVERTEC V250 S LINCOLN 5 B 1 OPERATION B 1 Read and understand this entire section before operating your machine SAFETY INSTRUCTIONS A WARNING ELECTRIC SHOCK can kill TX e Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground Always wear dry insulating gloves FUME
16. For Diesel Engines The Above For Gasoline 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 copy of Safety in Welding amp Cutting ANSI Standard 249 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 Sem 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 refueling to prevent spilled fuel from vaporiz ing on
17. 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 HIGH FREQUENCY PRECAUTIONS If possible locate the V250 S away from radio con trolled machinery The normal operation of the V250 S may adversely affect the operation of RF con trolled equipment which may result in bodily injury or damage to the equipment INPUT CONNECTIONS The Invertec V250 S should be connected only by a qualified electrician Installation should be made in accordance with all local and national electric codes and the information detailed below GROUND CONNECTION Ground per National Electrical Code for 60Hz machines connect the green lead to earth ground For 50 60Hz machines connect the ground terminal marked located in the machine on the lower right side the base of the welder to earth ground INPUT SUPPLY CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the rear of the machine Supply line entry provision is in the case rear panel POWER INPUT CONNECTION FOR 60HZ MACHINES A 10 ft power cord is provided and wired into the machine Follow the power cord connection instruc tions Incorrect connection may result in equipment damage Single Phase Input Connect green lead to ground per U S National Electrical Code Connect black and white leads to power Wrap red lead with tape t
18. Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode eo s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located
19. contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known welders should use the following procedures in order to In some cases it may be necessary to remove safety abs mis minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not a
20. helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understan
21. information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lOrders 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 l include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS 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 amp 99 99 915 00 For order value between 100 00 amp 149 00 For North America
22. invoiced orders over 50 00 4 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 METHOD OF PAYMENT Sorry No C O D Orders Name CHECKONE See Please Invoice only if order is over 50 00 220200000200 TTT Check or Money Order Enclosed U S Funds only nn nnn 55 5 1 Credit Card Telephone I Signature as it appears on Charge howto LLLLLLLLLLLLLLLLLLLL esos LU Le THIS FORM ORDER looks OR FREE INFORMATIVE CATALOGS incon Welding School l ED 80 Seminar Information ED 45 New Lessons in Arc Welding Procedure Handbook T we How to Read Shop Drawings Educational Video Information Incentive Management ED 93 A New Approach to Industrial Economics ames F Lincoln Arc Welding e American Century of ohn Lincoln 5 00 AC Foundation Book Information Welding Preheat Calculator ___ JFLF 515 Pipe Welding Charts Additional Shipping Costs if any rat cost 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 _____________ _ Code
23. lines 2 Remove the 5 16 hex head screws from the side 8 and top of the machine and remove wrap around machine cover 3 Be careful not to make contact with the capacitor terminals that are located in the top and bottom of the Power Board MAINTENANCE WARNING D 1 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locate the four capacitor terminals large hex head cap screws shown in Figure D 1 One pair at the top and one pair at the bottom of the Power Board Use electrically insulated gloves and insulated pli ers Hold body of the resistor and connect resistor leads across the two capacitor terminals Hold resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat discharge procedure for the capacitor on other two terminals Check voltage across terminals of all capacitors with a DC voltmeter Polarity of capacitor terminals is marked on PC board above terminals Voltage should be zero If any voltage remains repeat this capacitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD INSULATED GLOVES UPPER CAPACITOR TERMINALS LOWER CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS INVERTEC V250 S LINCOLN 5 D 2 MAINTENANCE D 2 ROUTINE MAINTENANCE 1 Perf
24. loose or faulty welding Service Facility performance The arc pops out cables Is the electrode DRY Try weld ing with another electrode from a different container Make sure you have the correct electrode for the application 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 LINCOLN 8 F 1 DIAGRAMS 10102 10103 WIRING DIAGRAM CODES Jequunu epoo juowudinbs e 10 juotuyedeg 20S ou 01 si ou j sjeued 5 y zo euo uo episul poised si e oul jenueuu siy Aq IS 104 eq jou 08261 JOHLNOO 109100 310W3H 4399141 810 99 MY19 YOLVOIGNI QVO TH3AO JOHINOO AMIS 9 JOHINOO SONV LONGNI 30804 vH IOH1INOO u HOLIMS 310W34 17901 55 HOLIMS eS 45913 d3d SIOANAS 1V914191 13 J19v1d3903H 1041 009 310W3uH TS 049 44 gt 9 11N LL gid gt N 93 GL A _NWN 3 gt aie 0
25. original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims INVERTEC V250 S LINCOLN E 1 2 TROUBLESHOOTING amp REPAIR 2 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 The input power switch must be no fan in the ON position Make sure the input voltage is correct for the machine 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 Check that the input voltage set fand the problem persists Contact up switch and jumper A the your local Lincoln Authorized Field reconnect auxiliary jumper in Service Facility the proper position for the input voltage being applied Refer to Input Vo
26. 1 territi n dtd rnt rint nx va v ea eee D 2 FILTER CAPACITOR CONDITIONING 2 D 2 LOCATION OF MAINTENANCE COMPONENTS eee eene eene nnn D 3 LIGiU N lo d lc SECTION E PC BOARD TROUBLESHOOTING PROCEDURES ins E 1 TROUBLESHOOTING GUIDE trt eee treu ra E teer E 2 DIAGRAMS c SECTION F PARTS MANUAL TE P 244 SERIES INVERTEC V250 S LINCOLN 5 1 INSTALLATION 1 Technical Specifications Invertec V250 S K1436 1 K1437 1 amp K1437 3 INPUT Standard Voltage 208 230 460 60Hz 200 220 400 440 50 60Hz 380 415 50Hz Input Current at Rated Output Model 34 32 16 35 33 18 17 20 18 60Hz 50 60 Hz 50Hz Standard Voltage 208 230 460 60Hz 200 220 400 440 50 60 Hz Inp ut Current at Rated Output Model 59 57 29 58 58 30 30 60Hz 50 60 Hz RATED OUTPUT THREE PHASE SINGLE PHASE Volts at Volts at Rated Amps Rated Amps 30 271 30 28 32 28 32 26 5 26 5 281 30 261 30 29 32 28 32 26 5 26 5 30 28 26 Model 60Hz 60Hz 60Hz 50 60Hz 50 60Hz 50 60Hz 50Hz 50Hz 50Hz Model 60Hz 60Hz 60Hz 50 60Hz 50 60Hz 50 60Hz Duty Cycle 35 Duty Cycle 60 Duty Cycle 100 Duty Cycle 35 Duty Cycle 60 Duty Cycle 100 Duty Cycle 35 Duty Cycle 60 Duty Cycle 100 Duty Cycle Duty Cycle 3596 Duty Cycle 60 Duty Cycle 100 Duty Cycle 85 Duty Cycle 60 Duty Cycle 100 Duty Cycle OUT
27. 200 amps and below 2 The electronic protection circuit in the V250S will limit the current to approximately 290 amps TIG WELDING The V250S is capable of touch start TIG welding An electrode cable work cable Arc Start Switch or Amptrol TIG torch and gas supply with regulator are required Refer to Accessories section of this manual Touch starting is done as follows 1 Place the shield cup edge on the work piece 2 Rock the tungsten down to touch 3 Trigger the output 4 Gently rock back the tungsten from the work 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 LINCOLN P 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
28. 250 S LINCOLN 8 TABLE OF CONTENTS vi PAGE INSTALLATION e SECTION A TECHNICAL SPECIFICATIONS 77 A 1 amp A 2 SAFETY PRECAUTIONS AE Pn RETANA ENANA A 3 SELECT SUITABLE LOCATION aa anaa aaia A 3 INPUT CONNECTIONS theta eret re rt rn ida rd ine EEES A 3 INPUT VOLTAGE RECONNECT 7 A 4 OUTPUT CONNECTIONS teneant rx eR d ea trente ae te ete uou 5 eld m SECTION B SAFETY INSTRUCTIONS niii iei e ertet Coin e Lo sie ena a a B 1 GENERAL DESCRIPTION tot dr era aar eo nu tct draenei B 1 CONTROLS AND SETTINGS iit rit aeree ed e acer da de B 2 CONSTANT CURRENT PROCESSES eviii ieii auiii i e a dies B 3 PARALLEL OP RATION ior Pete erae e th PR Gand REA dede B 4 OVERLOAD PROTECTION ee rn Ote breed s ue nct de dede date eate va a B 4 THERMAL PROTECTION sand tt itn nr cer de B 4 ACCESSORIES SECTION C OPTIONS ACCESSORIES co v eie cte t ta ee RTL TR uer x sud C 1 CABLE PLDUGS CER HER De Reda C 1 REMOTE CONTROLS E s ved ee dv n eege C 1 D Lidgidpuec SECTION D INPUT FILTER CAPACITOR DISCHARGE PROCEDURE D 1 ROUTINE MAINTENANGE
29. 6 052 O93 1H3ANI ONIHIM 200 u3MOd ce 6005 yeoz 4e 108 UE IN No 440 INN TS HOLIMS 103NNOO3H AHVNIEd zoz olo 902 78 m 800 ELECTRICAL DIAGRAMS F 4 F 4 10467 WIRING DIAGRAM CODE Jequunu e JO juotuyedeg 20S 01 si eui j sjeued einsoj oue euo uo y juo 92u919j9J 104 S SIUL episui pejsed si e 10 oyroeds jenueu siy Aq JO eq jou Aew y L0661 JOHINOO 109110 31084 t a 81 N ALOWSY 19 2 gt 22 N WOL1VOIONI QvOTH3AO WWYSHL OHINOO 18715 LOH Sd JOHINOO 39401 vH lOH1NOO EH HOLIMS ISO 99000 AR HOLIMS 100 1 eS 310v1d303H 10 1 00 31038 NIW 26919 Yad SIOANAS 1v9Ig8 10313 94 gt 9 Lx LL gt 9 805 9 SL 90 GL A MOTHBA 33009 40109 LINOUIO OL M N SIVNINHAL LO3NNOO 53009 1V9IH10313 1V901 TVNOLLVN Hd 3NIHOVIN LNdNI 3SVHd 33HHL 40 3416 LN3NOdWOO WOH3 GIMAIA 39N3N03S SNIH38WAN ALIAVO HOLO3NNOO ess 39v 0000 2000 DESCH P r
30. EX THEW ein eis s ALD al gl pis e Sug Wu AI uie Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo e Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo EROS SCRHBREUCF aU RRR DESSSSRSHSR ez 12 59 s ESSAI didi due de Lily putes cl gal e A s d READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez u
31. HO SLNANOdWOO 19 VX3 201 MOHS LON AYN SIHL QuvO8 1314 100 Y 40 ALFTIBY3SNVHOU3LNI JHL 9NLEO343V ANOHLIM 39NVHO AVIA QHVOS LINDHIO GALNIHd V 40 HO SIN3NOdNWOO JOONIS LIN9HI9 Add NS OL M D STWNIWHAL LO3NNOO 4009 1VOIH10313 1 201 ANY IVNOLLVN 43d 3NIHOVIN INdNI 3SvHd HIHHL HOS OLM 0 SIVNINHAL LOSNNOO 53000 1VOIHLO3T3 WOOT ANY IVNOLLVN Had ANIHO VIN UNI 3SvHd 2 TONIS HOS 318VO LNANI HLIM 5 LON 5 HOS OL 50 31 ALIHM 39 18 LO3NNOO 3009 91419373 1 43d OL QV31N3389 LO3NNOO INdNI 3SvHd 33HHL NOLLVINSNI A009 AGIAOHd OL 3dv L Qv31 OCH dvuM Add NS OL SAYIT 3LIHM 9 MOV T8 LOINN 3009 01810313 OL 0 31 N3389 193NNOO SSVHd 3 TONIS HOS 2 Eu NANI HLIM 5 S3NIHOVIN HOS 26919 Yad SIOANAS 1v9Ig810313 319v1d303H OHLNOO 31038 ip aye o Lx LL gt 5 38 8i 4 eet Wa av t 93 gt 81 N 31038 19 2 92a gt 228 618 WOLVOIONI VY QvOTH3AO WWYSHL 4 L t YAWHYOISNVYL cc 0 917 e erh DE 5 EH A800 2002 40 3016 LN3NOdWOO 3oN3no3S ALIAVO HOLOANN
32. I NMOHS NOILOANNOO 39V L10A LNdNI NOLLO3NNOO NO QV31 30V ld H38AiN 3309 NOWNOO Y AHUTOHI HO 5 LOVX4 JHL MOHS LON AVIN WVHDVIG SIHL 313 1dWO0 v 40 ALITIBV3ONVHOHW3INI JHL SNILO333V LNOHLIM AVIN GSLNIdd V 40 HO SLNINOdWOO JONIS LINOUIO ATddNS OL M 9 D STVNIIWH3L LO3NNOO 53809 1V9IH10313 17901 ANY TWNOILWN H3d 3NIHOVIN LndNI 3SvHd 338H1L 803 OL M STVNIIWH3I LOJNNOO 53009 1V9IH10313 1V901 ANY TVNOLLVN H3d 3NIHOVIN LNdNI 3SVHd TIONIS HOS 314V9 1ndNI HLIM 03119918 LON SANIHOVW OL SQV313 LIHM 9 MOVIE L93NNOO 2000 91419313 TIVNOLLVN 83d O1 QV31N33H9 LO3NNOO LNdNI 3SvHd 22001 404 NOILVINSNI A009 OL 34 1 HLIM QV31 AlddAS OL SQV313LIHM 8 MOVIE LO3NNOO 3009 91419413 TVNOLLVN Had OL QV31 N33H9 LOANNOO LNdNI 3SVHd 404 314V9 1ndNI HLIM 93119909 S3NIHOVIN HOJ H3 HOJSNVHL VON Ska Ory Xy Agir lt 8 HH ES ep e OS EH A802 ON MYLO 00 27 x viene 1 Yoe 130890 J 2 ph GIE ie EL 602 el 926 ell 128 lt i OL 706 6 lt i 8 606 lt 1 lae 9 oee lt 9 9 6 v vee lt 6 4 gle lt 1 axel Mz 007
33. IM490 C INVERTEC V250 S ban 200 For use with machines having Code Numbers 10102 10103 10187 10188 10304 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 150 9001 7 4 EET SY Under a Quality prre CERTIFICATE NUMBER 30278 LINCOLN Copyright 2001 Lincoin Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above
34. L RANGE IS 1 10 1 is VERY SOFT 10 IS VERY CRISP Recommended Adjustment Range Nominal Setting Process EXX18 thru 5 EXX28 stick 1 gentle may stick to 9 forceful more spatter EXX10 thru EXX14 stick 31010 Air Carbon Arc None Cutting 7 Output Terminals These quick disconnect termi nals provide connection points for the electrode and work cables Refer to Output Connections in the Installation chapter for proper cable sizes For positive polarity welding connect the electrode cable to the positive terminal and the work cable to the negative terminal To weld negative polarity reverse the electrode and work cables 8 Thermal Shutdown Indicator This light will illumi nate if an internal thermostat has been activated Machine output will return after the internal components have returned to a normal operating temperature See Thermal Protection later in this chapter CONSTANT CURRENT PROCESSES MANUAL ARC WELDING STICK The Invertec may be utilized as a manual DC arc welder with the electrode cable work cable and elec trode holder being the only equipment required AIR CARBON ARC CUTTING Air carbon arc cutting may be performed with the Invertec within its output rating using 5 32 3 9mm and 3 16 4 7mm diameter carbon rods Output cables an air carbon arc electrode cable assembly and a source of compressed air are required NOTE 1 Best performance will be at settings of
35. MPTOMS MISADJUSTMENT S COURSE OF ACTION No output Main input fuses open indicating excessive current draw The machine operates normally when connected for 200 280VAC input There is no output when the machine is connected to 380VAC or higher OUTPUT PROBLEMS 1 Inspect input leads for possible shorts or grounds or mis connec tions 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 Check the input voltage and input Service Facility voltage reconnect procedures See Installation Section of this manual 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 LINCOLN 8 6 TROUBLESHOOTING amp REPAIR E 6 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 be normal operation 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 pr
36. OO 9 8 ests 9 g 4 E LE ml Cal et Er 1IN9419 3A1L93104d TANvd 3015 1331 NOUS 35 8 TANVd H31N39 OHINOO Y FILS 9 lt 1H wee wel JP NI Me 30H03 6 1 vd 16 4 616 4 622 4 21 YNISLYJH Ser H3MOd UO 126 01 816 toe lt 6 Ge 0 8 ale LE SYOLOW 96 Moi IlOH1NOO 10110 EH 7777 608 4 9 018 4 lt 5 LIE O are MO 502 4 9 S JINISLV3H 8431411934 1ndino HANHOASNVEL NIV HOLIMS INVERTEC V250 S LINCOLN E ELECTRICAL DIAGRAMS F 3 10304 WIRING DIAGRAM CODE 310N34 1V901 ES HOLIMS 100 1 eS 1V901 31038 VE0 Ux 99000 37 amp MY19 00 27 140900 T 2 voe Jay Mo Quvog ESCH SCH gle y vee LE 2 sis k dr 028 JNDUS Sep G Lle 0 808 4 1 108 1 9 b 0i 4 ep ae ne 3015100 11084 05 0 6 026 10 80 Se 802 802 v40c K 0 0091 HAWNHOASNVEL 1339912 Ka coz Quvog 902 AC Loz 460 veoz 1 09 0091 HO rr toz au IT P veo 900 39
37. PUT THREE PHASE SINGLE PHASE Welding Current Range 1 250 Amps Constant Open Circuit Voltage 65 80 VDC Welding Current Range 1 250 Amps Constant Open Circuit Voltage 65 80 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES THREE PHASE SINGLE PHASE Input Voltage Frequency 208 60 230 60 460 60 200 50 60 220 50 60 400 50 60 440 50 60 Fuse Superlag or Breaker Size Input Ampere Rating on Nameplate Type 75 C Copper Wire in Conduit AWG IEC Sizes Type 75 C Copper Ground Wire in Conduit AWG IEC Sizes 10 6mm 10 6mm 10 6mm 10 6mm 10 6mm 12 Amm 12 Amm Input Voltage Frequency 208 609 230 609 460 60 200 50 60 220 50 60 400 50 60 440 50 60 Fuse Superlag or Breaker Size PHYSICAL DIMENSIONS Input Ampere Rating on Nameplate Type 75 C Copper Wire in Conduit AWG IEC Sizes 8 8 4mm 8 8 4mm 10 6mm 8 8 4mm 8 8 4mm 10 6mm 10 6mm Type 75 C Copper Ground Wire in Conduit AWG IEC 1 Based on a 10 min period f 200 amp 208VAC input may not meet NEMA IEC specifications at 250 Amps 2 Input voltage must be within 10 of rated value 2 Inp g INVERTEC V250 S LINCOLN 8 A 2 INSTALLATION A 2 Technical Specifications Invertec V250 S K1437 2 Standard Input Current Standard Input Current Voltage at Rated Output Voltage at Rated Out
38. S AND GASES 2 can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone GOUGING SPARKS can cause fire or explosion 7 Ke Keep flammable material away Do not weld cut or gouge on containers that have held com bustibles ARC RAYS can burn L Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual GENERAL DESCRIPTION The Invertec V250 S is a 250 amp arc welding power source that utilizes single or three phase input power to produce constant current output The welding response of this Invertec has been optimized for stick SMAW and TIG GTAW OPERATIONAL FEATURES The Invertec V250 S provides continuous total range output current adjustment selectable welding modes and local or remote output control Welding character istics can be controlled via an arc force control Additionally starting characteristics can be adjusted via a hot start control WELDING CAPABILITY The Invertec V250 S is rated at 250 amps 35 duty cycle based on a 10 minute cycle It is also rated at 165 amps 100 duty cycle and 200 amps 60 duty cycle LIMITATIONS The V250 S is not recommended for pipe thawing The V250 S should not be powered from the auxiliary power supply of an engine welder Special protection circuits may operate causing loss of ou
39. VIN HANHOASNVEL AH WT E ON pre Gen go gt gt y ASIE e pH 08 5 a rd EH A80c os A XVN MO 1 TT 2 TONA 9 126 4 61e eel 626 6 21 Ser sze el CY 16 0 08 K 6 Sr ae 0 1 Ae 9 5 QUE den RS LE lt e 2 TEC 5 6 L 4880204 e sose 4 dea bh op Ze toe p cf 1308 90 I 2 voe S M 5 XOL MO 1V901 31038 BLE Z Qquvoa JOH1NOO H3INHOJSNVU L LU 00v L00 ra E 3QISNI Lb 3aisino 1NOHJ 902 102 3QISNI 11084 2015110 yova ova M 4 02 i 60 9 ele qe 6 LIE r DIE 10 6 806 lt K 800 800 H3AHOJSNVUL 900 900 Sa 0 10 702 700 9z IT 19 X 2002 KI 1H Nr M LNdNI 00 Gre 097 009 100 v202 7 SN ie 02 202 902 0S 0091 HOLIMS 193NNOO3H 75 iu S 0SCA WVH9VIG ONIHIM juo 104 SI 3141 310 INVERTEC V250 S LINCOLN E 2 Jequunu epoo 1ueuudinbe y e 104 eorues eu 01 9 si
40. d the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 LINCOLN 8 WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Hecommended Safe Practices for the
41. ien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne soudage Utiliser des lune
42. ltage Reconnect Procedure in the Installation Chapter 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 LINCOLN 8 E 3 TROUBLESHOOTING amp REPAIR E 3 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 The Local Remote switch S3 must be in the LOCAL position unless a remote control device is attached to the remote receptacle 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 The machine may be overheated jand 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
43. n ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UttRc5cuc 9 fsPBHEICTASSUCFEU Fat in e zc EUR E fE FEES aH e SH7IAE 2 247 2154 75747 7 amp AHBSMAS Qai oe Jung dul ae bacs jaa e ois uui ARA ge cal sd ue e Turn power off before servicing e Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico e toque as partes el tricas nuas XLFFYA Y EAKCRU PRE gt TKS e RK SHA AGS HEAS Aie Aa ai Qd dg ghil Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes mo
44. o pro vide 600V insulation Three Phase Input Connect green lead to ground per U S National Electrical Code Connect black red and white leads to power INVERTEC V250 S LINCOLN 8 4 INSTALLATION 4 POWER INPUT CONNECTION FOR 50 60 HZ MACHINES 1 Connect terminal marked e 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 to earth ground The Invertec V250 S machine is supplied with one cord connector The cord connector provides a strain relief for the input power cord as it passes it through the rear access hole On K1436 1 K1437 1 and K1437 8 the cord connector is designed for a cord diameter of 7 9 to 27 2mm 310 to 1 070 in On K1437 2 the cord connector is designed for a cord diameter of 11 4 to 20 0mm 450 to 790 in Strip away outer jacket of cord trim fillers and insert conductors through cord connector The jacketed por tion of the cord must go through the cord connector Tighten both connector screws INPUT FUSE AND SUPPLY WIRE Refer to the Technical Specifications page at the beginning of this chapter for the proper fuse sizes and supply cable sizes Fuse the input circuit with recommended super lag fuses or delay type circuit breakers Install the proper fuse in the fuse holder in the main disconnect panel RECONNECT PROCEDURE 1 BE SURE POWER SWITCH IS OFF 2
45. oduce this low current until the protection circuit is reset Reset occurs when the output load is removed If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Check the input voltage and input voltage reconnect procedures See Input Voltage Reconnect Procedure 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 LINCOLN 8 7 TROUBLESHOOTING amp REPAIR E 7 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 Make sure the machine settings output power is low are correct for the weld process being used Check machine performance on LOCAL control If OK then the remote control device may be faulty Check or replace 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 Poor stick electrode welding Check for
46. 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 LINCOLN 8 4 TROUBLESHOOTING amp REPAIR 4 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 41 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 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 Remote output control not Make sure the Local Remote Service Facility functioning The machine operates switch S3 is in the REMOTE normally on LOCAL control position 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 LINCOLN 8 TROUBLESHOOTING amp REPAIR Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SY
47. orm 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 detail at the beginning of this chapter 3 Keeping the machine clean will result in cooler operation and higher reliability Be sure to clean the following areas with a low pressure air stream See figure D 2 for component locations e Power and control printed circuit boards e Power switch e Main transformer e Inputrectifier e Heat sink fins Input Filter Capacitors 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
48. per Wire in Conduit AWG IEC Sizes 8 8 4mm 8 8 4mm 10 6mm 8 8 4mm 8 8 4mm 10 6mm 10 6mm Type 75 C Copper Ground Wire in Conduit AWG IEC Sizes 10 6mm 10 6mm 10 6mm 10 6mm 0 6mm 10 6mm 0 6mm 3 INSTALLATION A 3 Read this entire installation section before you start installation SAFETY PRECAUTIONS 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 discharge capacitors with the procedure outlined in the Maintenance Section of this manual before working in that area of the equipment SELECT SUITABLE LOCATION The Invertec V250 S will operate in harsh environ ments Even so it is important that simple preventa tive measures are followed in order to assure long life and reliable operation The machine must be located where there is free cir culation of clean air such that air movement in the back and out the front will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles STACKING V250 S s cannot be stacked TILTING
49. 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 LINCOLN C1 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
50. put 220 440 35 Duty Cycle 34 17 220 440 35 Duty Cycle 57 29 400 6096 Duty Cycle 16 50 60 Hz 400 6096 Duty Cycle 27 50 60 Hz 220 400 440 10096 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 Model 50 60 Hz Model 50 60 Hz Volts at Rated Amps Volts at Duty Cycle Model Duty Cycle Rated Amps Model 35 Duty Cycle 60 Duty Cycle 100 Duty Cycle 30V 28V 26 2V 50 60Hz 50 60Hz 50 60Hz 35 Duty Cycle 60 Duty Cycle 100 Duty Cycle 29V 27 6V 26 2V 50 60Hz 50 60Hz 50 60Hz OUTPUT THREE PHASE SINGLE PHASE Welding Current Range Constant Open Circuit Voltage Welding Current Range Constant Open Circuit Voltage RECOMMENDED INPUT WIRE AND FUSE SIZES THREE PHASE SINGLE PHASE Type 75 C Fuse Superlag Input or Voltage Breaker Frequency Size 208 60 230 60 460 60 200 50 60 220 50 60 400 50 60 440 50 60 1 Based on a 10 min period Input Ampere Rating on Nameplate Type 75 C Copper Wire in Conduit AWG IEC Sizes 2 Input voltage must be within 10 of rated value 3 Excluding 400V VAC Input Copper Ground Wire in Conduit AWG IEC Sizes Fuse Superlag Input or Voltage Breaker Frequency Size 208 609 230 609 460 60 200 50 60 220 50 60 400 50 60 440 50 60 INVERTEC V250 S LINCOLN 5 Input Ampere Rating on Nameplate Type 75 C Cop
51. quired using an Arc Start Switch Amptrol or similar means Short circuit current is limited to approx imately 25 amps to aid in touch starting CC Soft Best for EXX18 thru EXX28 stick electrodes Output energized when machine is on CC Crisp Use this mode for stick welding with EXX10 thru EXX14 electrodes Output energized when machine is on Hot Start Controls the amount of starting energy in SMAW The Hot Start setting will set the amount of extra power given during the initial strike A Hot Start setting of 100 will give you an additional striking current 100 above the welding set current Striking current in this example will be 200 of the set current For a Hot Start setting of 100 the current will decrease back to the set current in one second A Hot Start setting of 50 will give you an additional striking current 50 above the welding set current Striking current in this example will be 150 of the set current For a Hot Start setting of 50 the current will decrease back to the set current in 5 second The maximum striking current is 300 Amps INVERTEC V250 S LINCOLN B 3 OPERATION 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 RECOMMENDED ARC FORCE INDUCTANCE SETTINGS FOR SELECTED APPLICATIONS FUL
52. th 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 contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental
53. tic build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the P C Board must be either conductive anti static or static dissipative Remove the P C Board from the static shielding bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a static charge If the P C Board can t be installed immediately put it back in the static shielding bag f the P C Board uses protective shorting jumpers don t remove them until installation is complete If you return a P C Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the fail ure symptom has been corrected by the replacement PC board NOTE It is desirable to have a spare known good PC board available for PC board trou bleshooting NOTE Allow the machine to heat up so that all electrical components can reach their oper ating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem If the original problem does not reap pear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring har ness junction blocks and terminal strips b If the
54. tput INVERTEC V250 S LINCOLN P B 2 B 2 CONTROLS AND SETTINGS OPERATION 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 Q NG SMAW SMAW CRISP Te iN REMOTE LOCAL THERMAL o 120 250 E HOT START 5 6 12 T AS 5 UV n WS 7 677 e 6 170 INVERTEC 0250 5 eo CH O 2 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 Output Control This controls the output current Control is provided over the entire output range of the power source with 1 turn of the control knob This control may be adjusted while under load to change power source output When using remote control this function becomes the limit setting Local Remote Switch Place in the LOCAL position to allow output adjustment at the machine Place in the REMOTE position to allow output adjustment at remote pot or amptrol In Remote the machine output control pot is the limit setting for remote control Mode Switch GTAW Optimized for touch start use Triggering at amphenol is re
55. ttempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground
56. ttes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2
57. ventes opere com os paineis abertos ou guardas removidas EX CRMRBIEELEWTEEU CRRRIARRARS SHR Ro e 20 Sel dos Asal L t Cols Vil ual lu Qai ye Aale Viel Al ll WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it ie BR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR HORM PRMOX A NHERBEE lt RA E ENUCPFSU tL THHORAMEI ETF SU RA ET MEL BE SUCR Rr de OE ND RES AMENER Ss So 0 Gaul FAS EH HAS ESSA BHC VT Aal veel d aul d AAL s i Gail Ca L LINCOLN ELECTRIC World s Leader in Welding and Cutting P roducts 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
Download Pdf Manuals
Related Search