IM802-C
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INVERTEC V275-S
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful 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.
™
10993, 11001,11164, 11165, 11224
11225, & 11446
February, 2011
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
____________________________________________________
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 vaporizing on 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.
____________________________________________________
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.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
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.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
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
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
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.
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.
___________________________________________________
1.g. 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.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
ii
SAFETY
ii
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) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. 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.
FUMES AND GASES
can be dangerous.
5.a. 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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.d. 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.
vapors
to
5.e. Read and understand 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.f. Also see item 1.b.
iii
SAFETY
iii
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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.
6.b. 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.
6.c. 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.
6.d. 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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
6.g. 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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler 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 couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de nʼimporte quelle
partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude
ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la
debrancher à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Thank You
vv
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
CUSTOMER ASSISTANCE POLICY
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.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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 V275-S
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions. ..............................................................................................................A-2
Suitable Location..................................................................................................................A-2
Stacking ........................................................................................................................A-2
Tilting.............................................................................................................................A-2
High Frequency Protection............................................................................................A-2
Input Connections ................................................................................................................A-2
Input Fuse and Supply Wire..........................................................................................A-2
Input Supply Connections .............................................................................................A-2
Power Input Connections ..............................................................................................A-2
Input Voltage Reconnect Procedure ....................................................................................A-3
Output Connections..............................................................................................................A-4
Remote Control Receptacle ..........................................................................................A-4
Output Cables ...............................................................................................................A-4
Quick Disconnect Plugs ................................................................................................A-4
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ...............................................................................................................B-1
General Description..............................................................................................................B-1
Operational Features ....................................................................................................B-1
Welding Capability ........................................................................................................B-1
Limitations .....................................................................................................................B-1
Controls and Settings ....................................................................................................B-2,B-3
Constant Current Processes ................................................................................................B-3
Parallel Operation.................................................................................................................B-3
Overload Protection..............................................................................................................B-3
Thermal Protection ...............................................................................................................B-3
Fan ......................................................................................................................................B-3
Power-Up Sequence ............................................................................................................B-3
________________________________________________________________________________
vi
Accessories ........................................................................................................Section C
General Options / Accessories..............................................................................C-1
Cable Plugs.....................................................................................................C-1
Remote Control ............................................................................................................
________________________________________________________________________________
C-1
Maintenance........................................................................................................Section D
Input Filter Capacitor Discharge Procedure ..........................................................D-1
Routine Maintenance.............................................................................................D-2
Filter Capacitor Conditioning .................................................................................D-2
Location of Maintenance Components..................................................................D-3
________________________________________________________________________________
Troubleshooting .................................................................................................Section E
Safety Precautions.................................................................................................E-1
PC Board Troubleshooting Procedures.................................................................E-2
Troubleshooting Guide.............................................................................E-3 thru E-7
________________________________________________________________________________
Wiring Diagrams and Dimension Print .............................................................Section F
________________________________________________________________________________
Parts Pages ....................................................................................................P-476 Series
________________________________________________________________________________
INVERTEC V275-S
A-1
INSTALLATION
Technical Specifications - Invertec V275-S
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS-Hz
OUTPUT
CONDITIONS
INPUT
CURRENT
AMPS
IDLE
POWER
A-1
EFFICIENCY
@ RATED
OUTPUT
27/25/13/11
34/33/17/14
38/37/19/16
25/15/15/14/13
32/20/19/18/17
208/230/460/575V - 60Hz
220/380/400/415/440 - 50Hz
200A@28V.100%
250A@30V. 60%
275A@31V. 35%
200A@28V.100%
250A@30V. 35%
INPUT AT RATED OUTPUT - SINGLE PHASE ONLY
INPUT VOLTS-Hz
208/230/460/575V - 60Hz
220/380/400/415/440 - 50Hz
OUTPUT
CONDITIONS
200A@28V.100%
250A@30V. 60%
275A@31V.* 35%
200A@28V.100%
250A@30V. 35%
INPUT
CURRENT
AMPS
49/48/26/21
63/62/33/27
68/67/38/31
48/32/30/29/27
63/42/40/38/36
OUTPUT (THREE AND SINGLE PHASE)
WELDING NO LOAD
CURRENT RANGE VOLTAGE
5-275 Amps 70 VDC
RECOMMENDED MINIMUM INPUT WIRE AND FUSE SIZES
THREE PHASE SINGLE PHASE
Input Voltage-Hz
208/230-60
460/575-60
220-50
380/400/415-50
440-50
Cord Size AWG(mm2)
based on a type S, SJ, SJO
or SJT Flexible cord
in 30°C Ambient
8(8.4)
14(2.5)
8(8.4)
12(4)
14(2.5)
Fuse Size
(Time Delay Fuse)
Amps
60
35
60
35
35
Input Voltage-Hz
208-60
230-60
460/575-60
220-50
380/400/415-50
440-50
PHYSICAL DIMENSIONS
Height Width Depth
13.6in.(345mm) - Handle Folded Down 20.25 in.(514mm)
9.0 in.(229mm)
16in.(406mm) - Handle Up
21.7 in.(551)-With Cord Strain Relief
TEMPERATURE RANGES
150W Max
IDLE
POWER
87%
EFFICIENCY
@ RATED
OUTPUT
150W Max
Cord Size AWG(mm2)
based on a type S, SJ, SJO
or SJT Flexible cord
in 30°C Ambient
6(16)
6 (16)
10 (6)
6(16)
8(10)
10(6)
87%
1
1
1
Weight (With Cord)
Fuse Size
(Time Delay Fuse)
Amps
100
100
60
100
60
60
54.5lbs. (24.7Kg)
OPERATING TEMPERATURE RANGE
-20°C to +40°C
(1) When operating on these inputs, the line cord may need to be changed
* On 208VAC Single Phase the 35% duty cycle output rating is 275A @ 29V
INVERTEC V275-S
STORAGE TEMPERATURE RANGE
-40°C to +40°C
A-2
Read this entire installation section before you
start installation.
INSTALLATION
SAFETY PRECAUTIONS
A-2
TILTING
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.
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and
service 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 V275-S will operate in harsh environments. Even so, it is important that simple preventative measures are followed in order to assure long life
and reliable operation.
• The machine must be located where there is free circulation of clean air such that air movement in the
back and out the front will not be restricted.
HIGH FREQUENCY PROTECTION
Locate the Invertec V275-S away from radio controlled machinery.
CAUTION
The normal operation of the Invertec V275-S may
adversely affect the operation of RF controlled
equipment, which may result in bodily injury or
damage to the equipment.
-----------------------------------------------------------------------
INPUT CONNECTIONS
The Invertec V275-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.
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.
• 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.
• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
CAUTION
Where there is a combustible surface directly
under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at
least .06”(1.6mm) thick, which shall extend not
less than 5.90”(150mm) beyond the equipment on
all sides.
-----------------------------------------------------------------------
STACKING
V275-Sʼs cannot be stacked.
INVERTEC V275-S
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
A 10 ft. power cord is provided and wired into the
machine. Follow the power cord connection instructions. Incorrect connection may result in equipment
damage.
Single Phase Input: Connect green lead to ground
per National Electrical Code. Connect black and white
or brown leads to power. Wrap red lead with tape to
provide 600V insulation.
Three Phase Input: Connect green lead to ground
per National Electrical Code. Connect black, red and
white or brown leads to power.
A-3
INSTALLATION
INPUT VOLTAGE RECONNECT
PROCEDURE
When received directly from the factory, units are connected for, 460 VAC. If 460 VAC is the desired input,
then the machine may be connected to the power system without any setup required inside the reconnect
door. For other voltages refer to the instructions located on the Reconnect Panel Access Door or follow the
instructions below.
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the
welder.
------------------------------------------------------------------------
1. Open the access door on the left side of the
machine.
A-3
2. For 208-230: Position the large switch to 208-230.
For 380-575: Position the large switch to 380-575.
3. Move the “A” lead to the appropriate terminal.
Refer to figure A.1 below.
S21230-
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A.
A
VOLTAGE=208-230V
VOLTAGE=380-575V
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
208V
REPLACE WITH SPECIFIED FUSE.
220-230V
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
'A'
380-415V
use or service this equipment.
440-460V
Only qualified persons should install,
575V
.
Do not touch electrically live parts.
.
INPUT VOLTAGE RANGE.
removed.
2. CONNECT LEAD 'A' TO DESIRED
Do not operate with wraparound
.
inspecting or servicing machine.
1. BE SURE POWER SWITCH IS OFF.
Disconnect input power before
.
RECONNECT PROCEDURE
RECONNECT PROCEDURE
1. BE SURE POWER SWITCH IS OFF.
2. CONNECT LEAD 'A' TO DESIRED
INPUT VOLTAGE RANGE.
575V
440-460V
380-415V
220-230V
208V
3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.
'A'
IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)
AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
REPLACE WITH SPECIFIED FUSE.
.
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,
use or service this equipment.
VOLTAGE=380-575V
THE L I NCOLN ELECTRI C CO. CLEVELAND, OHIO U.S.A.
Figure A.1 Input Voltage Reconnect Instructions
A
INVERTEC V275-S
VOLTAGE=208-230V
S21230-
A-4
OUTPUT CONNECTIONS
INSTALLATION
QUICK DISCONNECT PLUGS
A-4
Refer to figure A.2 for the location of the 6-Pin
Remote Receptacle and the Output Terminals.
FIGURE A.2 OUTPUT CONNECTIONS
6-PIN REMOTE RECEPTACLE
REMOTE
ON
OFF
OUTPUT TERMINALS
REMOTE CONTROL RECEPTACLE
Remote control (K857), Hand amptrol (K963) and
Foot amptrol (K870) connect directly to 6-pin amphenol on the front of the unit.
OUTPUT CABLES
Select the output cable size based on Table A.1.
TABLE A.1
Cable Sizes for Combined Length of Electrode and
Work Cable ( Copper Cable Rated at 75°C).
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.
BOOT
WELDING CABLE
25 mm
1 in.
TRIM
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.
SET SCREW
Length Cable Size
up to 150 ft.(46m) 1/0 (50mm
up to 250 ft.(72m) 2/0 (70mm2)
2
)
INVERTEC V275-S
COPPER TUBE
BRASS PLUG
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.
B-1
OPERATION
B-1
Read and understand this entire section before
operating your machine.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such
as output terminals or internal wiring.
• Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
____________________________________
FUMES AND GASES
can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
____________________________________
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion
GENERAL DESCRIPTION
The Invertec V275-S is a 275 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 V275-S provides continuous total range
output current adjustment, selectable welding modes
and local or remote output control. Welding characteristics can be controlled via an arc force control.
Additionally, starting characteristics can be adjusted
via a “hot start” control.
WELDING CAPABILITY
The Invertec V275-S is rated at 275 amps, 35% duty
cycle (based on a 10 minute cycle). It is also rated at
200 amps, 100% duty cycle, and 250 amps, 60% duty
cycle.
LIMITATIONS
The V275-S is not recommended for pipe thawing.
• Keep flammable material away.
• Do not weld, cut or gouge on
containers that have held com-
bustibles.
____________________________________
ARC RAYS
can burn.
• Wear eye, ear and body
protection.
____________________________________
Only qualified personnel should operate this equipment. Observe all safety information throughout this
manual.
INVERTEC V275-S
B-2
OFF
OPERATION
B-2
CONTROLS AND SETTINGS
All operator controls and adjustments are located on the case front of the V275-S. Refer to Figure B.1 and corresponding explanations.
FIGURE B.1 — CASE FRONT CONTROLS.
2
8
3
LOCAL
REMOTE
4
CC STICK
TIG
9
ARC FORCE
-10
REMOTE
7
1. POWER SWITCH - Place the lever in the “ON”
position to energize the machine. When the power is on
the output will be energized in STICK (SMAW) mode and
TIG (GTAW) if the remote is set to local control. At
power up the thermal Light and Fan will turn on for
approximately 3 seconds.
OUTPUT
+10
10
HOT START
ON
OFF
5
6
ON
OFF
TIG (GTAW) Optimized for touch start use. Short circuit
current is limited to approximately 20 amps to aid in touch
starting.
In TIG (GTAW) mode, the Local/Remote switch also controls if the output is energized.
1
2. 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.
3. 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.
4. MODE SWITCH
CC -Stick (SMAW) Use this mode for all stick welding.
Output energized when machine is on.
INVERTEC V275-S
MODE LOCAL/REMOTE SWITCH OUTPUT
GTAW LOCAL ENERGIZED
GTAW REMOTE CONTROL BY
REMOTE ARC
SWITCH
SMAW LOCAL & REMOTE ENERGIZED
5. HOT START - Controls the amount of starting ener-
gy in CC Stick (SMAW). The Hot Start can be either
turned on or off. When on, it provides a striking current at
160% of the set current or 275A whichever is larger then
quickly reverts to the set current in 0.4 second.
B-3
6. ARC FORCE - This control functions in CC Stick SMAW
modes to adjust the Arc Force. The arc is soft at the minimum settings and more forceful or driving at the maximum
settings. Higher spatter levels may be present at the maximum settings. Full range is from -10(Soft) to +10(Crisp)
OPERATION
* Note: Operating this machine with the output control set to
B-3
maximum may cause the machine to phase back and the arc
to go out. This occurs because the welding current exceeded
300 amps and the machineʼs protection circuitry activated.
Turn the output control down to correct this condition.
7. OUTPUT TERMINALS - These quick disconnect termi-
nals provide connection points for the electrode and work
cables. Refer to Output Connection 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
illuminate 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 Operation chapter.
PARALLEL OPERATION
The Invertecʼs are operable in parallel. For best results, the currents of each machine should be reasonably 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 parallel will not be effective due
to the voltage requirements of procedures in that power range.
To set machine outputs, start with output control pots and arc
force pots in identical positions. Adjust outputs and arc forces to
maintain current sharing while establishing the proper output
current.
9. 6-PIN REMOTE RECEPTACLE
(Refer to Output Connection in the Installation chapter.)
10. POWER LIGHT - This Light will illuminate when the
power switch is in the “ON” position.
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 electrode 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 3/16” diameter carbon rods. Output
cables, an air carbon arc electrode cable assembly, and a
source of compressed air are required.
TIG WELDING*
The Invertec V275-S is capable of touch start TIG welding. An
electrode cable, work cable, 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, if using remote control.
4. Gently rock back the tungsten from the workpiece.
Note: The short circuit current is limited to 20 amps to aid in
touch starting. Panel output control becomes the current
limit setting when in remote control.
OVERLOAD PROTECTION
The machine is electrically protected from producing high output
currents. Should the output current exceed 300A, an electronic
protection circuit will reduce the current to less than 200A. The
machine will continue to produce this low current until the protection circuit is reset. Reset occurs when the output load is
removed.
Note: When TIG welding with the Output Knob at or above 275
Amps the Arc may go out.
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.
FAN
The cooling fan on the V275-S operates once 15 amps of welding current is drawn and for 7 minutes after the output current
has stopped flowing.
The fan will also run anytime the machine has over heated.
POWER-UP SEQUENCE
At power up the thermal light (and Power light on codes 11164
and above) turns on and the fans run for approximately 3 seconds. This is the pre-charge time for the main capacitors. After
this time the fans and thermal light turn off and the pre-charge
relay closes to apply full line power to the capacitors. At this
time the machine is ready to weld.
INVERTEC V275-S
C-1
ACCESSORIES
C-1
OPTIONS / ACCESSORIES
REMOTE OUTPUT CONTROL - Consists of a control
box with choice of two cable lengths. Permits remote
adjustment of output, 6 pin connection.
Order K857 for 25 ft. (7.6m) or
K857-1 for 100 ft. (30.5m)
Twist-Mate Cable Plug - For connecting welding
cable to output terminal receptacles. For 1/0-2/0 (50-
2
70mm
Order K852-70
Twist-Mate Cable Plug - For connecting welding
cable to output terminal receptacles. For 2/0-3/0 (7095mm
Order K852-95
Twist-Mate Cable Receptacle - For connecting weld-
ing cable to Twist-Mate cable plug. For 1/0-2/0 (5070mm2) cable.
Order K1759-70
Twist-Mate Cable Receptacle - For connecting weld-
ing cable to Twist-Mate cable plug. For 2/0-3/0 (7095mm2) cable.
Order K1759-95
Twist-Mate Plugs and Receptacles are not used
with Code 11446.
TIG OPTIONS
Twist-Mate Torch Adapter - For connection of PTA-9
or PTA-17V torches (1 piece cable) to power sources
without as passing through the Twist-Mate connection.
Order K960-1
) cable.
2
) cable.
TIG OPTIONS
Hand Amptrol - may be used in place of the Foot
Amptrol. Fastens to the torch for convenient thumb
control. Comes with a 25 ft. (7.6m) cable.
Order K963-1 (for smaller handle 9, 17 or 20 series
torches.)
Order K963-2 (for larger handle 18 or 26 series torches.)
STICK OPTIONS
Accessory Kit - Complete kit for stick welding.
Includes 30 ft. (9.1m) #3 electrode cable, 25 ft. (7.6m)
#3 work cable, headshield, work clamp and electrode
holder.
Order K704 for 400 Amps
Order K875 for 200 Amps.
K2269-1, V275-S Includes:
• V-275-S
• Twist-Mate Cable Plugs (K852-70), qty 2
V275-S 4-Pack and 8-Pack Inverter Racks Includes:
• Inverter Rack
• An ideal system to group several inverter power
sources in an industrially designed portable package. Entire system meets National Electric Code
(NEC) standards.
• Includes 4 or 8 Invertec V275-S rack model power
sources. This special rack version has all the same
features as the standard V275-S.
Foot Amptrol™ - Varies current while welding for
making critical TIG welds and crater filling. Depress
pedal to increase current. Depressing pedal fully
achieves maximum set current. Fully raising the
pedal finishes the weld and starts the after flow cycle.
Includes 25 ft. (7.6m) control cable.
Order K870
INVERTEC V275-S
D-1
MAINTENANCE
D-1
WARNING
ELECTRIC SHOCK can kill.
• Have an electrician install and service
this equipment.
• Turn the input power off at the fuse
box before working on equipment.
• Do not touch electrically hot parts.
• Prior to Performing preventative maintenance, perform the following capacitor discharge procedure to avoid electric shock.
---------------------------------------------------------------------
INPUT FILTER CAPACITOR
DISCHARGE PROCEDURE
1. Turn off input power or disconnect input power
lines.
2. Remove the 5/16" hex head screws from the side
and top of the machine and remove wrap-around
machine cover.
3. Be careful not to make contact with the capacitor
terminals that are located in the top and bottom of
the Power Board.
4. Obtain a high resistance and high wattage resistor
(25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A
SHORTING STRAP FOR THIS PROCEDURE.
5. 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.
6. Use electrically insulated gloves and insulated pliers. 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.
7. Repeat discharge procedure for the capacitor on
other two terminals.
8. 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
RIGHT SIDE OF MACHINE
CAPACITOR TERMINALS
UPPER
LOWER
CAPACITOR
TERMINALS
POWER
RESISTOR
INSULATED
PLIERS
INSULATED
GLOVES
INVERTEC V275-S
D-2
MAINTENANCE
ROUTINE MAINTENANCE
1. Perform the following preventive maintenance procedures at least once every six months. It is good
practice to keep a preventive maintenance record;
a record tag attached to the machine works best.
2. Remove the machine wrap-around cover and perform 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.
•Power and control printed circuit boards
•Power switch
•Main transformer
D-2
•Input rectifier
•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 breakage. 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 ohmmeter, measure resistance between either output
terminal and an unpainted surface of the machine
case. (See Figure D.2 for locations.) Meter reading
should be 500,000 ohms or more. If meter reading
is less than 500,000 ohms, check for electrical components that are not properly insulated from the
case. Correct insulation if needed.
7. Replace machine cover and screws.
INVERTEC V275-S
D-3
MAINTENANCE
FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
WRAP-AROUND
CENTER ASSEMBLY
D-3
CASE FRONT ASSEMBLY
OUTPUT TERMINALS
CHOKE ASSEMBLY
CONTROL PC BOARD
MAIN TRANSFORMER ASSEMBLY
POWER SWITCH
INPUT
RECTIFIER
OUTPUT
RECTIFIER
ASSEMBLY
CASE BACK ASSEMBLY
SWITCH BOARD &
HEAT SINK ASSEMBLY
COOLING FANS
BASE
INVERTEC V275-S
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
E-2
TROUBLESHOOTING & REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
E-2
WARNING
ELECTRIC SHOCK can kill.
Have an electrician install
and service this equipment. 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 properly connected.
3. If the problem persists, replace the suspect PC board using standard practices to
avoid static electrical damage and electrical shock. Read the warning inside the
static resistant bag and perform the following procedures:
- Remove the P.C. Board from the staticshielding bag and place it directly into the
equipment. Donʼt set the P.C. Board on or
near paper, plastic or cloth which could have
a static charge. If the P.C. Board canʼt be
installed immediately, put it back in the staticshielding bag.
- If the P.C. Board uses protective shorting
jumpers, donʼt 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 failure 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 troubleshooting.
NOTE: Allow the machine to heat up so that
all electrical components can reach their operating temperature.
5. Remove the replacement PC board and
substitute it with the original PC board to
recreate the original problem.
P.C. Board can be damaged by static electricity.
- Remove your bodyʼs static charge before opening
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
Reusable
Container
Do Not Destroy
equipment frame. Keep touching the frame to
prevent static 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-dissipate.
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.
- If you donʼt have a wrist
strap, touch an unpainted,
grounded, part of the
INVERTEC V275-S
a. 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 harness, junction blocks, and terminal
strips.
b. If the 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.
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-3
PROBLEMS
(SYMPTOMS)
Major physical or electrical damage
is observed when cover wrap-around
is removed.
The machine is dead - no output.
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. The input power switch must be
in the ON position.
2. Make sure the input voltage is
correct for the machine.
3. If the machine is set for singlephase operation, inspect to
assure that the WHITE and
BLACK leads are connected
properly and the RED lead is not
connected and is insulated.
4. Check that the input voltage setup switch and jumper “A” (the
reconnect auxiliary jumper) are in
the proper position for the input
voltage being applied. Refer to
Input Voltage Reconnect
Procedure in the Installation
Chapter.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
5. Check continuity of the 0.6-amp
slow blow fuse located on the
reconnect panel.
No output but the fan operates normally.
1. If the machine has not been used
for a long time and is connected
for 380 VAC or higher, the
capacitors may need “conditioning”. See Input Filter Capacitor
Conditioning.
2. The machine may be overheated.
Check the thermal indicator light.
Wait for the machine to cool and
the thermostats to reset.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-4
PROBLEMS
(SYMPTOMS)
Output turns on momentarily, then
switches off and repeats cycle.
Remote output control not
functioning. The machine operates
normally on LOCAL control.
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. Check the input voltages and
reconnection procedures. Make
sure the input voltage is correct
for the machine. See Input
Voltage Reconnect Procedure.
2. Check or replace remote control
device. (If used)
1. Make sure the Local/Remote
switch (S3) is in the REMOTE
position.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
2. The remote control device may
be faulty. Replace.
3. The Local/Remote switch must
be in the LOCAL position unless
a remote control device is
attached to the remote
receptacle.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-5
PROBLEMS
(SYMPTOMS)
No output - Main input fuses open,
indicating excessive current draw.
The machine operates normally
when connected for 200 - 230VAC
input. There is no output when the
machine is connected to 380VAC or
higher.
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. Inspect input leads for possible
shorts or grounds or mis-connections.
2. Install new fuses and reapply
power. If fuses open again, consult a Lincoln Authorized Field
Service Facility.
1. Check the input voltage and input
voltage reconnect procedures.
See Installation Section of this
manual.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-6
PROBLEMS
(SYMPTOMS)
The machine will not produce more
than 200 amps.
POSSIBLE
CAUSE
OUTPUT PROBLEMS
1. This may be normal operation. If
the output current exceeds 300
amps, an electronic protection
circuit will reduce the current to
less than 200 amps. The
machine will continue to produce
this low current until the
protection circuit is reset. Reset
occurs when the output load is
removed.
2. Check the input voltage and input
voltage reconnect procedures.
See Input Voltage Reconnect
Procedure.
3. Check for loose or faulty welding
cables.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
E-7
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-7
PROBLEMS
(SYMPTOMS)
Poor welding, weld settings drift, or
output power is low.
Poor stick electrode welding
performance. The arc pops out.
POSSIBLE
CAUSE
WELDING PROBLEMS
1. Make sure the machine settings
are correct for the weld process
being used.
2. Check machine performance on
LOCAL control. If OK then the
remote control device may be
faulty. Check or replace.
3. Check the input voltages and
input voltage reconnect
procedures. See Installation
Section of this manual.
4. Check for loose or faulty welding
cables.
1. Check for loose or faulty welding
cables.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Service Facility.
The thermal light and fan keep turning on and off.
2. Is the electrode DRY? Try welding with another electrode from a
different container. Make sure
you have the correct electrode for
the application.
3. Make sure the machine settings
are correct for the weld process
being used.
1. Check the input voltage section.
2. Check for blockage of vents,
which restricts air flow into or out
of the machine.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
F-1
ENHANCED DIAGRAM
DIAGRAMS
WIRING DIAGRAM- CODES: 10993, 11001
F-1
INVERTEC V275-S
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
ENHANCED DIAGRAM
ELECTRICAL DIAGRAMS
WIRING DIAGRAM- CODES: 11164, 11165, 11224, 11225, 11446
F-2
INVERTEC V275-S
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-3
ELECTRICAL DIAGRAMS
WIRING DIAGRAM- CODES:11267, 11268
F-3
INVERTEC V275-S
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the
machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-4
DIAGRAMS
15.89
16.84
F-4
A.02
L11981
1.44
20.25
DIMENSION PRINT
2.08
3.17 MAX
.79 MIN
OPEN
4.30 MAX
RECONNECT DOOR
11.85
.88
.35 TYP.
9.00
7.00
.93
1.25
O
O
.25
INVERTEC V275-S
NOTES
INVERTEC V275-S
WARNING
Spanish
AVISO DE
PRECAUCION
• Do not touch 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 mojada.
• Aislese del trabajo y de la tierra.
• Keep flammable materials away.
• Mantenga el material combustible
fuera del área de trabajo.
• Wear eye, ear and body protection.
• Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
• Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
• Isolez-vous du travail et de la terre.
• Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
• Isolieren Sie sich von den
Elektroden und dem Erdboden!
• Não toque partes elétricas e electro-
dos com a pele ou roupa molhada.
• Isole-se da peça e terra.
• Gardez à l’écart de tout matériel
• Entfernen Sie brennbarres Material!
• Mantenha inflamáveis bem guarda-
inflammable.
dos.
• Protégez vos yeux, vos oreilles et
votre corps.
• Tragen Sie Augen-, Ohren- und Kör-
perschutz!
• Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE
ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU
SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE
EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
SIND EBENFALLS ZU BEACHTEN.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
• Turn power off before servicing.
• Do not operate with panel open or
guards off.
WARNING
• Los humos fuera de la zona de res-
piración.
• Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
• Gardez la tête à l’écart des fumées.
• Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
• Vermeiden Sie das Einatmen von
Schweibrauch!
• Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
• Mantenha seu rosto da fumaça.
• Use ventilação e exhaustão para
remover fumo da zona respiratória.
• Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
• Débranchez le courant avant l’entre-
tien.
• Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen;
Maschine anhalten!)
•
Não opere com as tampas removidas.
•
Desligue a corrente antes de fazer
serviço.
•
Não toque as partes elétricas nuas.
• No operar con panel abierto o
• N’opérez pas avec les panneaux
• Anlage nie ohne Schutzgehäuse
• Mantenha-se afastado das partes
• Não opere com os paineis abertos
guardas quitadas.
ouverts ou avec les dispositifs de
protection enlevés.
oder Innenschutzverkleidung in
Betrieb setzen!
moventes.
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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