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IM490-C
™
February, 2001
INVERTEC V250-S
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 be
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 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. Us
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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 hos
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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 su
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� 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
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vi TABLE OF CONTENTS PAGE INSTALLATION .......................................................................................................................SECTION A TECHNICAL SPECIFICATIONS........................................................................................A-1 & A-2 SAFETY PRECAUTIONS ............................................................................................................A-3 SELECT SUITABLE LOCATION.......................................................
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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 (1) (1) Duty Cycle Amps Rated Am
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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
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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 V250-S may adversely affect the operation of RF con- SAFETY PRECAUTIONS 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
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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 n
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A-5 A-5 INSTALLATION QUICK DISCONNECT PLUGS OUTPUT CONNECTIONS 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 GTAW SMAW THERMAL SOFT CRISP HOT START 5 6 4 7 3 2. Slide rubber boot onto cable e
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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 response of this Invertec has been optimized for stick WARNING (SMAW) and TIG (GTAW). ELECTRIC SHOCK can kill. OPERATIONAL FEATURES � Do not touch electrically live parts such The Invertec V250-S provides continuous
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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 GTAW SMAW THERMAL SOFT CRISP HOT START 5 6 4 7 2 3 8 A 2 120 85 5 9 1 OUTPUT 0 10 170 3 50 15 ARC FORCE 230 REMOTE LOCAL 5 6 1 4 7 3 250 8 2 6 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 sti
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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
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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- m
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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. tm 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
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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
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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 +
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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
