IGBT INVERTER ARC WELDER

INV 250C
MAINTENANCE MANUAL

1. Safety
Never look at an arc without protection. Wear a helmet with safety goggles or glasses with side
shields underneath, with appropriate filter lenses protected by clear cover lens. Recommended
shade filter lens:
Amps TIG MMAW MIG PulsedMIG
0-100 10 9 10 12-13
100-150 11 10 10 12-13
150-200 12 10-11 11-12 12-13
200-300 13 11 12-13 12-13
300-400 14 12 13 14

Burn protection the welding arc is intense and visibly bright. Its radiation can damage eyes,
penetrate light-weight clothing, reflect from light colored surfaces, and burn the skin and eyes.
Wear protective clothing-leather or heat resistant gloves, hat and safety-toed boots. Avoid oily
or greasy clothing. A spark may ignite them. Hot metal such as electrode stubs and work pieces
should never be handled without gloves. Ear plugs should be worn when welding in overhead
position or in a confined space. A hard hat should be then others are working overhead.

Toxic fumes Adequate ventilation with air is essential. Severe discomfort, illness or death can
result from fumes, vapors, heat, or oxygen depletion that welding or cutting may produce.

Fire and explosion prevention Be aware that flying sparks or falling slag can pass through cracks,
along pipes, through windows or doors, and through wall or floor opening, out of sight of the
operator. Sparks and slag can travel up to 10 meters from the arc. Keep equipment clean and
operable, free of oil, grease, and (in electrical parts) of metallic particles that can cause short
circuits.

Shock prevention Exposed conductors or other bare metal in the welding circuit, or ungrounded
electrically alive equipment can fatally shock a person whose body becomes a conductor. Ensure
that the equipment is correctly connected and earthed. If unsure have the equipment installed
by a qualified electrician. On mobile or portable equipment, regularly inspect condition of trailing
power leads and connecting plugs. Repair or replace damaged leads.

Know your welder

 Torch connector

polarity shifting
negative output

Alarm light
voltage displayer

power light
welding mode
chooose
current displayer
2T/4T

inching wire
mma current/wire
feeding
feeding adjusting

gas checking

voltage under 电子 电抗 调节
MIG/ARC force electronic
under MMA : reactance
adjusting adjusting
 power switch
nameplate

gas input
input power line

fan

Inside structure

wire feeder
spool 流板
panel control
PCB
power switch

control transformer
Control PCB
rectifier

Main control PCB

Filter capacitor
small Loading-PCB

main transformer

Wind
hall sensor deflector

output
reactor
driving PCB

Mutual inductor IGBT

Fast recovery diode

(rectifier PCB)
 Main control PCB/Control PCB

Panel pcb connecting line wire feeder power connector

gas valve connector

控制板
Power supply
panel pcb connecting for wire
feeder

Communication power supplying line

interface for control CN101 for wire feeder
pcb and panel PCB

voltage feedback line

CN301
line for main
control PCB and Central socket
control line CN303
transformer CN8

voltage feedback line

2
CN7
connecting line for control
pcb and main control pcb
CN304

Hall sensor
connector

NTC line CN4 Mutual inductor Driving PCB driving

line CN1 transformer connector
CN901
Panel PCB
Program input
interface

communication
interface for
control PCB and
panel pcb
Circuit diagram
Key point testing
1）driving testing

Oscillograph

note：Frequency 20KHz±2KHz
Secondary rectify testing

Oscillograph

note：Frequency 20KHz±2KHz
Machine principle and debugging
INV 250C theory diagram

Function and technical requirements of each circuit

 Primary rectification and filtering circuit: convert the 50Hz AC input from the power grid into DC.

 Inverter circuit: convert the DC current of the power grid after rectification into stable high-frequency AC
current (43KHz).

 Transformer circuit： high frequency and high voltage AC current  converted into high frequency and low
voltage AC current.

 Secondary rectification: convert high frequency and low voltage AC current into DC current output.
 Drive circuit: provide the ON/OFF signal required by IGBT inverter power device.
 Auxiliary power supply: provide stable low voltage DC power supply to control circuit and drive circuit
 Current setting and feedback circuit: get sample of  the output current and give feedback signal to the control
circuit to ensure stable output of the whole machine.

4.Key components on main circuit

INPUT RECTIFY and FILTER CIRTUIT

Single phase rectifier Transfer AC into DC

CBB capacitor Smooth the DC voltage

INVERTER CIRCUIT
 Transfer from low frequency
IGBT DC into 20khz high frequency
AC

Main transformer Transfer from HF high voltage

into HF low voltage power.

SECOND TIME RECTIFY

Fast recovery diode (FRD) Transfer from HF AC into HF

DC power

Mutual inductor Sample the output Amps and

supply stable output.

Note: IGBT and FRD looks very similar, please read the descriptions carefully to make sure you
don’t use the wrong part before you do repair.
1) Key components testing
Rectify Bridge
Two ways to check whether rectifier is working properly:
Use a pointer multi-meter, set it at Rxlk.
Red pen connect to DC +, black pen to DC -, it should read12kΩ; if connect the pens oppositely, it
should read + infinite.
Red pen connect to DC +, black pen to AC-, it should read 5kΩ; if connect the pens oppositely, it
should read + infinite.
Black pen connect to DC -, red pen to AC -, it should read 5kΩ.
Use digital type multi-meter, set it at DIODE.
Black pen connect to DC +, red pen to DC -, it should read 0.87V.
Red and black pens each connect to AC -, it should read 0.47V.
Red pen connect DC -, black pen connect to AC -, it should read 0.47V.
 AC （ ~
DC （ +

DC （ -

Conclusion: if resistance between all the 4 points is smaller than the value described above, it
means the rectifier is shocked through already; if the values all infinite high, it means the
rectifier is break, the whole circuit is open.

IGBT
Two ways to check whether IGBT is working properly:
Use a pointer multi-meter, set it at Rxlk.
Discharge the IGBT by short circuit the 3 terminals firstly.
Measure resistance between G and E, G and C, no matter by what direction, it should read
infinite high.
Red pen connect to terminal C, black to E, it should read 5kΩ.

Use digital type multi-meter, set it at DIODE.

Voltage between E and C should be 0.45V.
Conclusion: if resistance between all the 3 points is smaller than the value described above, it
means the IGBT is shocked through already; if the values all infinite high, it means the IGBT is
break, the whole circuit is open.
Fast recovery diode (FRD)
Two ways to check whether FRD is working properly:
Use a pointer multi-meter, set it at Rxlk.
Red pen connect to terminal #2 (see below image), black pen to terminal #1, it should read 3kΩ;
if change to opposite direction it should be infinite high.
Red pen connect to terminal #2, black pen to terminal #3, it should read 5kΩ; if change to
opposite direction it should be infinite high.
Use digital type multi-meter, set it at DIODE.
Black pen connect to terminal #2 (see below image), red pen to terminal #1, it should read 0.36V;
if change to opposite direction it should be infinite high.
Black pen connect to terminal #2 (see below image), red pen to terminal #3, it should read 0.36V;
if change to opposite direction it should be infinite high.
1 3
2
Conclusion: if resistance between all the 3 terminals is smaller than the value described above,
it means the FRD is shocked through already; if the values all infinite high, it means the FRD is
break, the whole circuit is open.

Trouble shooting
INV 250C series IGBT welding machine technology is mature, the performance is stable and reliable, but the welding
machine is different from the household appliances, mostly using under poor environment, so generally speaking,
there is some failure during using. From the maintenance point of view, there are only three kinds:
1. Device reasons, such as component damage, poor connecting for plug sockets etc.;
2. External reason, such as external power grid voltage beyond the range, poor input/output connection, etc.;
3. Human causes, such as damage in transportation, improper use and maintenance, improper operation in repair,
etc.
For maintenance personnel, when repairing the welding machine, they should first judge the cause of the fault
according to the fault phenomenon, whether it is inside or outside the machine. Then, through on-site observation,
they should check by themselves in order to quickly and accurately find the fault point.

1. Fault phenomenon: After turn on switch, the power indicator is not on.
failure reason:
(1) The input power line is not connected well to the grid;
(2) The internal getting circuit of the input power line ;
(3) The line associated with the power switch getting off
(4) Power switch damage;
⑸ power switch has problem.
Trouble shooting :
Use a multimeter to measure the grid voltage and confirm whether the grid voltage is normal.
Confirm whether the input power line is reliably connected with the power grid;
(3) Turn off power , remove the fixing screw on the shell, open the machine shell, first confirm the internal connection
good or not, using the steps shown as below to eliminate or reduce the fault range:

Step 1: Use a multimeter to measure there is AC415V± 15% or not between the two
input lines of the power switch.  To judge the internal is circuit or not
 Yes No

Step 2: Use a multimeter to measure there is  AC220V± 15% on the power line problem
main control board (CN8). To judge power switch broken or not

No Yes
有 Step 3: At the moment when the power switch is turned on, use a multimeter to measure rectifier
power switch problem
bridge to check have AC220V± 15% or not  To judge the starting circuit is damaged or not

Step 4: At the moment when the power switch turn on, use a multimeter to
measure the control pcb (CN304)  to check have +15V/-15V  to judge
switch power broken or not
if no voltage, the starting circuit
problem

 protection circuit failure for abnormality

switch power problem

2. Fault phenomenon: when the power switch is turned on, the power indicator light is not on, the panel has no
display, but the fan rotates normally.
failure reason:
(1) The line between the control panel PCB and the control PCB connecting good or not
Trouble shooting:
Open the casing and check whether the wiring is off or broken;
If falling off, plug again or change new line if line broken

3, fault phenomenon: the panel display is normal, MMA is normal, MIG no wire feeding cannot do welding.
failure reason:
1.Welding torch switch is broken
2. Output voltage feedback wire of control PCB is broken or dropped off;
3 The wire connecting between control PCB to the wire feeder breaks or falls off;
4.The control pcb broken
5.The wire feeder is broken
Trouble shooting :
Press the welding torch switch to measure whether the output of the welding machine is about 72V. If so, it is normal.
If not, the torch switch is broken;
(2) Use a multimeter to measure the voltage feedback interface on the control board; Whether the measurement is
about 72V, if so, it is normal; If not, the output voltage feedback line breaks or falls off;
(3) Use a multimeter to measure the wire feeder power supply interface on the control board. If there is voltage, the
wire feeder is broken or the wire falls off between wire feeder and control board. If not, the control is broken

4, no output, panel voltage display is "0" :

Failure reason
(1) The voltage feedback wires between auxiliary power supply and main control board are broken or fall off;
(2) The drive signal wire connected to the main control board broken or falling off;
(3) There is no output driving signal on the driving PCB, and the driving PCB is broken. To measure the voltage &
frequency of the drive signal with an oscilloscope.