Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
IM802-B
INVERTEC V275-S April, 2006
For use with machines having Code Numbers: 10993, 11001,11164, 11165, 11224
11225, 11267 & 11268
OPERATORS MANUAL
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame may be dangerous
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
3.f. Maintain the electrode holder, work clamp, welding cable and 5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace coming from degreasing, cleaning or spraying operations.
damaged insulation. The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating
3.g. Never dip the electrode in water for cooling. products.
3.h. Never simultaneously touch electrically hot parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturers instructions for this
3.i. When working above floor level, use a safety belt to protect equipment and the consumables to be used, including the
yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employers safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to Safety in Welding and Cutting (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact A safe distance from arc welding or cutting operations and
can cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically hot parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been cleaned. For information, purchase Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
Precautions for Safe Handling of Compressed Gases in
Cylinders, available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturers
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturers recommendations.
Mar 95
iv iv
SAFETY
5. Toujours porter des lunettes de scurit dans la zone de
PRCAUTIONS DE SRET soudage. Utiliser des lunettes avec crans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones o lon pique le laitier.
tions et les prcautions de sret specifiques qui parraissent
dans ce manuel aussi bien que les prcautions de sret 6. Eloigner les matriaux inflammables ou les recouvrir afin de
gnrales suivantes: prvenir tout risque dincendie d aux tincelles.
Sret Pour Soudage A LArc 7. Quand on ne soude pas, poser la pince une endroit isol de
1. Protegez-vous contre la secousse lectrique: la masse. Un court-circuit accidental peut provoquer un
chauffement et un risque dincendie.
a. Les circuits llectrode et la pice sont sous tension
quand la machine souder est en marche. Eviter toujours 8. Sassurer que la masse est connecte le plus prs possible
tout contact entre les parties sous tension et la peau nue de la zone de travail quil est pratique de le faire. Si on place
ou les vtements mouills. Porter des gants secs et sans la masse sur la charpente de la construction ou dautres
trous pour isoler les mains. endroits loigns de la zone de travail, on augmente le risque
b. Faire trs attention de bien sisoler de la masse quand on de voir passer le courant de soudage par les chaines de lev-
soude dans des endroits humides, ou sur un plancher age, cbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques dincendie ou dechauffement des chaines et des
les positions assis ou couch pour lesquelles une cbles jusqu ce quils se rompent.
grande partie du corps peut tre en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-lectrode, la pince de masse, le cble Ceci est particulirement important pour le soudage de tles
de soudage et la machine souder en bon et sr tat galvanises plombes, ou cadmies ou tout autre mtal qui
defonctionnement. produit des fumes toxiques.
d.Ne jamais plonger le porte-lectrode dans leau pour le
refroidir. 10. Ne pas souder en prsence de vapeurs de chlore provenant
e. Ne jamais toucher simultanment les parties sous tension doprations de dgraissage, nettoyage ou pistolage. La
des porte-lectrodes connects deux machines soud- chaleur ou les rayons de larc peuvent ragir avec les
er parce que la tension entre les deux pinces peut tre le vapeurs du solvant pour produire du phosgne (gas forte-
total de la tension vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sret,
pour le porte-lectrode sapplicuent aussi au pistolet de voir le code Code for safety in welding and cutting CSA
soudage. Standard W 117.2-1974.
Mar. 93
v v
Thank You to take pride in operating this Lincoln Electric Company product
as much pride as we have in bringing this product to you!
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.
- 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 WEB SITE at www.lincolnelectric.com. Choose Quick Links and then
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:
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 vi
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
________________________________________________________________________________
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
________________________________________________________________________________
INVERTEC V275-S
A-1 INSTALLATION A-1
Technical Specifications - Invertec V275-S
INPUT AT RATED OUTPUT - THREE PHASE ONLY
INPUT VOLTS-Hz OUTPUT INPUT IDLE EFFICIENCY
CONDITIONS CURRENT POWER @ RATED
AMPS OUTPUT
200A@28V.100% 25/15/15/14/13
220/380/400/415/440 - 50Hz 32/20/19/18/17
250A@30V. 35%
200A@28V.100% 48/32/30/29/27
220/380/400/415/440 - 50Hz 63/42/40/38/36
250A@30V. 35%
PHYSICAL DIMENSIONS
Height Width Depth Weight (With Cord)
13.6in.(345mm) - Handle Folded Down 20.25 in.(514mm)
9.0 in.(229mm) 54.5lbs. (24.7Kg)
16in.(406mm) - Handle Up 21.7 in.(551)-With Cord Strain Relief
TEMPERATURE RANGES
OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE
-20C to +40C -40C to +40C
(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
A-2 INSTALLATION A-2
Dirt and dust that can be drawn into the machine INPUT SUPPLY CONNECTIONS
should be kept to a minimum. Failure to observe Be sure the voltage phase and frequency of the input
these precautions can result in excessive operating power is as specified on the rating plate, located on
temperatures and nuisance shutdown. the rear of the machine.
Keep machine dry. Shelter from rain and snow. Do Supply line entry provision is in the case rear panel.
not place on wet ground or in puddles.
POWER INPUT CONNECTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
A 10 ft. power cord is provided and wired into the
CAUTION machine. Follow the power cord connection instruc-
tions. Incorrect connection may result in equipment
damage.
Where there is a combustible surface directly
under stationary or fixed electrical equipment,
Single Phase Input: Connect green lead to ground
that surface shall be covered with a steel plate at
per National Electrical Code. Connect black and white
least .06(1.6mm) thick, which shall extend not
or brown leads to power. Wrap red lead with tape to
less than 5.90(150mm) beyond the equipment on
provide 600V insulation.
all sides.
-----------------------------------------------------------------------
Three Phase Input: Connect green lead to ground
STACKING per National Electrical Code. Connect black, red and
white or brown leads to power.
V275-Ss cannot be stacked.
INVERTEC V275-S
A-3 INSTALLATION A-3
CAUTION
Failure to follow these instructions can cause
immediate failure of components within the
welder.
------------------------------------------------------------------------
RECONNECT PROCEDURE
. Disconnect input power before
1. BE SURE POWER SWITCH IS OFF. inspecting or servicing machine.
2. CONNECT LEAD 'A' TO DESIRED . Do not operate with wraparound
INPUT VOLTAGE RANGE. removed.
. Do not touch electrically live parts.
575V . Only qualified persons should install,
440-460V use or service this equipment.
VOLTAGE=380-575V VOLTAGE=208-230V
INVERTEC V275-S
OFF
A-4 INSTALLATION A-4
OUTPUT CONNECTIONS QUICK DISCONNECT PLUGS
Refer to figure A.2 for the location of the 6-Pin A quick disconnect system is used for the welding
Remote Receptacle and the Output Terminals. cable connections. The welding plug included with the
FIGURE A.2 OUTPUT CONNECTIONS machine is designed to accept a welding cable size of
1/0 to 2/0.
6-PIN REMOTE RECEPTACLE
REMOTE 1. Remove 1 in. (25mm) of welding cable insulation.
OFF
BOOT
WELDING CABLE
25 mm
OUTPUT TERMINALS TRIM
1 in.
INVERTEC V275-S
B-1 OPERATION B-1
____________________________________
ARC RAYS
can burn.
____________________________________
INVERTEC V275-S
B-2 OPERATION B-2
2
8
3
LOCAL
10
REMOTE OUTPUT
HOT START
4 CC STICK ARC FORCE
ON 5
OFF
1. POWER SWITCH - Place the lever in the ON TIG (GTAW) Optimized for touch start use. Short circuit
position to energize the machine. When the power is on current is limited to approximately 20 amps to aid in touch
the output will be energized in STICK (SMAW) mode and starting.
TIG (GTAW) if the remote is set to local control. At
power up the thermal Light and Fan will turn on for In TIG (GTAW) mode, the Local/Remote switch also con-
approximately 3 seconds. trols if the output is energized.
2. OUTPUT CONTROL - This controls the output MODE LOCAL/REMOTE SWITCH OUTPUT
current. Control is provided over the entire output range
GTAW LOCAL ENERGIZED
of the power source with (1) turn of the control knob. This
control may be adjusted while under load to change
GTAW REMOTE CONTROL BY
power source output. When using remote control this
REMOTE ARC
function becomes the limit setting.
SWITCH
INVERTEC V275-S
B-3 OPERATION B-3
6. ARC FORCE - This control functions in CC Stick SMAW * Note: Operating this machine with the output control set to
modes to adjust the Arc Force. The arc is soft at the mini- maximum may cause the machine to phase back and the arc
mum settings and more forceful or driving at the maximum to go out. This occurs because the welding current exceeded
settings. Higher spatter levels may be present at the maxi- 300 amps and the machines protection circuitry activated.
mum settings. Full range is from -10(Soft) to +10(Crisp) Turn the output control down to correct this condition.
INVERTEC V275-S
C-1 ACCESSORIES C-1
REMOTE OUTPUT CONTROL - Consists of a control Hand Amptrol - may be used in place of the Foot
Amptrol. Fastens to the torch for convenient thumb
box with choice of two cable lengths. Permits remote
control. Comes with a 25 ft. (7.6m) cable.
adjustment of output, 6 pin connection.
Order K963-1 (for smaller handle 9, 17 or 20 series
Order K857 for 25 ft. (7.6m) or torches.)
K857-1 for 100 ft. (30.5m) Order K963-2 (for larger handle 18 or 26 series torch-
es.)
Twist-Mate Cable Plug - For connecting welding
cable to output terminal receptacles. For 1/0-2/0 (50- STICK OPTIONS
70mm2) cable.
Order K852-70 Accessory Kit - Complete kit for stick welding.
Includes 30 ft. (9.1m) #3 electrode cable, 25 ft. (7.6m)
Twist-Mate Cable Plug - For connecting welding #3 work cable, headshield, work clamp and electrode
cable to output terminal receptacles. For 2/0-3/0 (70- holder.
95mm2) cable. Order K704 for 400 Amps
Order K852-95 Order K875 for 200 Amps.
Twist-Mate Cable Receptacle - For connecting weld- K2199-2, V275-S 8-Pack Inverter Rack Includes:
ing cable to Twist-Mate cable plug. For 2/0-3/0 (70-
95mm2) cable. Inverter Rack
Order K1759-95
An ideal system to group several inverter power
sources in an industrially designed portable pack-
TIG OPTIONS age. Entire system meets National Electric Code
(NEC) standards.
Twist-Mate Torch Adapter - For connection of PTA-9
or PTA-17V torches (1 piece cable) to power sources Includes 8 Invertec V275-S rack model power
without as passing through the Twist-Mate connec- sources. This special rack version has all the same
tion. features as the standard V275-S. Standard power
Order K960-1 cord is replaced by individual stranded wires to
meet NEC standards.
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
1. Turn off input power or disconnect input power 7. Repeat discharge procedure for the capacitor on
lines. other two terminals.
2. Remove the 5/16" hex head screws from the side 8. Check voltage across terminals of all capacitors
and top of the machine and remove wrap-around with a DC voltmeter. Polarity of capacitor terminals
machine cover. is marked on PC board above terminals. Voltage
should be zero. If any voltage remains, repeat this
3. Be careful not to make contact with the capacitor capacitor discharge procedure.
terminals that are located in the top and bottom of
the Power Board.
POWER UPPER
BOARD CAPACITOR TERMINALS
LOWER
CAPACITOR
TERMINALS
POWER
RESISTOR
INSULATED
GLOVES
INVERTEC V275-S
D-2 MAINTENANCE D-2
ROUTINE MAINTENANCE
1. Perform the following preventive maintenance pro-
cedures 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.
Power switch
Main transformer
Input rectifier
Output Terminals
INVERTEC V275-S
D-3 MAINTENANCE D-3
WRAP-AROUND
CENTER ASSEMBLY
POWER SWITCH
OUTPUT TERMINALS
BASE
INVERTEC V275-S
E-1 TROUBLESHOOTING E-1
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS). This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
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 E-2
P.C. Board can be dam- a. If the original problem does not reap-
aged by static electricity. pear by substituting the original
board, then the PC board was not the
- Remove your bodys stat- problem. Continue to look for bad
ic charge before opening connections in the control wiring har-
the static-shielding bag. ness, junction blocks, and terminal
ATTENTION Wear an anti-static wrist strips.
Static-Sensitive strap. For safety, use a 1
Devices Meg ohm resistive cord b. If the original problem is recreated by
Handle only at connected to a grounded the substitution of the original board,
Static-Safe part of the equipment then the PC board was the problem.
Workstations frame. Reinstall the replacement PC board
and test the machine.
Reusable
Container - If you dont have a wrist
6. Always indicate that this procedure was
Do Not Destroy strap, touch an unpainted,
followed when warranty reports are to be
grounded, part of the
submitted.
equipment frame. Keep touching the frame to
prevent static build-up. Be sure not to touch
NOTE: Following this procedure and writing on the
any electrically live parts at the same time.
warranty report, INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM, will help avoid
- Tools which come in contact with the P.C.
denial of legitimate PC board warranty claims.
Board must be either conductive, anti-static or
static-dissipate.
INVERTEC V275-S
E-3 TROUBLESHOOTING E-3
4. Check that the input voltage set- If all recommended possible areas of
up switch and jumper A (the misadjustment have been checked
reconnect auxiliary jumper) are in and the problem persists, Contact
the proper position for the input your local Lincoln Authorized Field
voltage being applied. Refer to Service Facility.
Input Voltage Reconnect
Procedure in the Installation
Chapter.
No output but the fan operates nor- 1. If the machine has not been used
mally. for a long time and is connected
for 380 VAC or higher, the
capacitors may need condition-
ing. See Input Filter Capacitor
Conditioning.
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 V275-S
E-4 TROUBLESHOOTING E-4
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 V275-S
E-5 TROUBLESHOOTING E-5
No output - Main input fuses open, 1. Inspect input leads for possible
indicating excessive current draw. shorts or grounds or mis-connec-
tions.
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 V275-S
E-6 TROUBLESHOOTING E-6
The machine will not produce more 1. This may be normal operation. If
than 200 amps. 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
If all recommended possible areas of
protection circuit is reset. Reset
misadjustment have been checked
occurs when the output load is
and the problem persists, Contact
removed.
your local Lincoln Authorized Field
Service Facility.
2. Check the input voltage and input
voltage reconnect procedures.
See Input Voltage Reconnect
Procedure.
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 V275-S
E-7 TROUBLESHOOTING E-7
Poor welding, weld settings drift, or 1. Make sure the machine settings
output power is low. are correct for the weld process
being used.
The thermal light and fan keep turn- 1. Check the input voltage section.
ing on and off.
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, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.
INVERTEC V275-S
F-1
207A
202A
D4 310 4 5 324 - Y +
3 J3 R1
307 5 6 B 304A 277
310 4 INPUT 8 J1 W B
207A 202A 313 7 375
5 A1
BRIDGE 308 9 8 303
J10 201
313 7 204 _ 309 7 9 377
307 8 201 REMOTE
L1 207A 311 10 10 328
308 2
377
376
375
204 TP2 C 11 304
309 6
375B
TP3 _F 12 330
SWITCH PC BOARD CONTROL PC BOARD
N.E. L2 207 1 387
317
318
B E
2 388
TP1
208 4 316 ARC FORCE
L3 209 5 320 ON SMAW
A +D 7 382
S4 208 375B
205 H1B 8 383
209 206 203A J2 R2
205 6 229 304A
209 10 4 324
R222 1
J4 11 2 303
W221 2
12 277
304
206
203A
C1 3 76 OFF GTAW
327
0.6 AMP 9 75 HOT 328
WELD
SLOW BLOW START MODE
A1 A
H3A
H1A H3A
207
206
380- 220-
202A
H4 H3 W or N L1 F
415V 230V (W) 4 E A 77
H3C 4 8
A
203A
FAN CR1 CR1 440- 2 D B 76
0 H6 H5 R L2
2 6 1 575V 460V (V) L5 C
REMOTE
N.C. N.A.
202
RECEPTACLE
H1C FAN RELAY 75
B L3
(U)
H1D
H3D H1C
S2A S2B G POWER SWITCH
FAN
202
203
203
H1D S1
229
H1 H2 H3 H4 H5 H6 TP6
PRIMARY RECONNECT SWITCHES
(REAR VIEW) TP4 TP5
204 J5 1 6 2 3 4 5 (SHOWN IN 380-575V POSITION)
205 320
N.D.
WIRING DIAGRAM- CODES: 10993, 11001
316 319 C3 C4
H1 H2 H3 H4 H5 H6
S5
C1,C2 SWITCH BOARD CAPACITORS, 2200/500 N.D.
T2
C3,C4 OUTPUT BY-PASS CAPACITORS, .05/600 W221
CR1 FAN RELAY COIL, 12V DC
AUXILIARY
SHUNT
R222
18V
U
317
W
D1A,D1B OUTPUT DIODE, S3 L3 384 R3
TRANSFORMER
W R OUTPUT
D2A,D2B OUTPUT DIODE, 208 318 CHOKE
385
387
388
L1,L2 OUTPUT REACTOR T3
W UT
RI
G
L3 OUTPUT INDUCTOR (CHOKE) I-O HT
L4,L5 RF TOROID CHOKES PR I-IN HEAT SINK
INVERTEC V275-S
PR
DIAGRAMS
R T4
R1 OUTPUT CONTROL POTENTIOMETER,10K/2 X4
3 OUTPUT RECTIFIER
R2 ARC FORCE POTENTIOMETER, 10K/2
R3,R4 OUTPUT LOAD RESISTORS, 100/25 C X4 X2
7 SE
S1 INPUT POWER SWITCH T L1
205 6 OS
S2A,S2B RECONNECT SWITCHES 2 BO
X7
S3 OUTPUT RECTIFIER HEATSINK THERMOSTAT REACTOR
381
UT
S4 SWITCH BOARD HEATSINK THERMOSTAT 201 I-O GND
PR X8 X8
S5 CHOKE THERMOSTAT X1 D1A D1B FROM AMPHENOL
I-IN CASE
T1 MAIN TRANSFORMER PR X3 X1 FRONT LINE CORD
GND1
T2 AUXILIARY TRANSFORMER
T3,T4 CURRENT TRANSFORMER C X7 GND2 G
SE D3A D3B
LE
TP1,TP2,TP3 INPUT MOV, 660V AC T X6
T1 OS CASE
FT
TP4,TP5 OUTPUT MOV, 320V AC BO X3 BACK
SNUBBER PC BOARD
MAIN BASE
X5
L2
LEAD COLORING CODE: COMPONENT VALUE
X5 UNITS:
REACTOR B-BLACK U-BLUE RESISTORS:
NOTES: G-GREEN W-WHITE OHMS/WATTS
O-ORANGE Y-YELLOW CAPACITORS:
N.A. MACHINES WITH RED, BLACK AND WHITE OR BROWN POWER CORDS: R-RED N-BROWN MFD/VOLTS
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.
CONNECT BLACK AND WHITE OR BROWN LEADS TO SUPPLY CIRCUIT. CONNECTOR PIN NUMBERS:
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
EXAMPLE: THIS IS PIN 7
ENHANCED
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. CONNECTION SHOWN IS FOR 575V OPERATION. 1 2 3 7 0F CONNECTOR J5
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.
WIRING DIAGRAM
A
G4365-1
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
F-1
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
207A
202A
D4 310 4 5 324 - Y +
3 J3 R1
307 5 6 B 304A 277
310 4 INPUT J1 W B
313 8 7 375
207A 202A BRIDGE
5 J10
201 A1 308 9 8 303
313 7 _ 309 7 9 377
307 8 204 201
L1 207A 311 10 10 328 POWER REMOTE
308 2
377
376
375
204 C 11 304
309 6 TP2 W B
375B
- G +
TP3 _F 12 330
SWITCH PC BOARD L2 CONTROL PC BOARD
N.E. 207 1 387
317
318
B E 2
TP1 388
208 4 316 ARC FORCE
L3 209 5 320 ON SMAW
A +D 7 382 B
S4 208 H1B 375B
205 8 383
209 206 203A J2 R2
205 6 229 304A
209 10 4 324
R222 1 J4 11 2 303
W221 2
12 277
304
206
203A
C1 3 76 OFF GTAW
9 75
327
328
0.6 AMP HOT WELD
SLOW BLOW START MODE
A1 A
H3A
H1A H3A
207
206
380- 220-
202A
H4 H3 W or N L1 F
415V 230V (W) 4 E A 77
H3C 4 8
CR1 A
203A
FAN CR1 H6 440- H5 2 D B 76
0 1 460V R L2
2 6 575V (V) L5 C
REMOTE
N.C. N.A.
202
RECEPTACLE
H1C FAN RELAY 75
B L3
(U)
H1D
H3D H1C
S2A S2B G POWER SWITCH
FAN
202
203
203
H1D S1
229
H1 H2 H3 H4 H5 H6 TP6
PRIMARY RECONNECT SWITCHES
(REAR VIEW) TP4 TP5
204 J5 1 6 2 3 4 5 (SHOWN IN 380-575V POSITION)
205 320
N.D.
316 319 C3 C4
H1 H2 H3 H4 H5 H6
S5
C1,C2 SWITCH BOARD CAPACITORS, 2200/500 N.D.
T2
C3,C4 OUTPUT BY-PASS CAPACITORS, .05/600 W221
CR1 FAN RELAY COIL, 12V DC
AUXILIARY
SHUNT
R222
18V
U
W
D1A,D1B OUTPUT DIODE, 317 S3 L3 384 R3
TRANSFORMER
W R OUTPUT
D2A,D2B OUTPUT DIODE, 208 318 CHOKE
385
387
388
L1,L2 OUTPUT REACTOR T3
W UT
RI
G
L3 OUTPUT INDUCTOR (CHOKE) I-O HT
L4,L5 RF TOROID CHOKES PR I-IN
R T4 PR HEAT SINK
INVERTEC V275-S
R1 OUTPUT CONTROL POTENTIOMETER,10K/2 X4
3 OUTPUT RECTIFIER
R2 ARC FORCE POTENTIOMETER, 10K/2
R3,R4 OUTPUT LOAD RESISTORS, 100/25 C X4 X2
7 SE
S1 INPUT POWER SWITCH T L1
205 6 OS
S2A,S2B RECONNECT SWITCHES 2 BO
X7
WIRING DIAGRAM- CODES: 11164, 11165, 11224, 11225,
UT
S4 SWITCH BOARD HEATSINK THERMOSTAT 201 I-O GND
PR X8 X8
S5 CHOKE THERMOSTAT X1 D1A D1B FROM AMPHENOL
I-IN CASE
T1 MAIN TRANSFORMER PR X3 X1 FRONT LINE CORD
GND1
T2 AUXILIARY TRANSFORMER
T3,T4 CURRENT TRANSFORMER C X7 GND2 G
ELECTRICAL DIAGRAMS
SE D3A D3B
LE
T X6
TP1,TP2,TP3 INPUT MOV, 660V AC T1 OS CASE
FT
BO X3 BACK
SNUBBER PC BOARD
L2
LEAD COLORING CODE: COMPONENT VALUE
X5 UNITS:
REACTOR B-BLACK U-BLUE RESISTORS:
NOTES: G-GREEN W-WHITE
N.A. MACHINES WITH RED, BLACK AND WHITE OR BROWN POWER CORDS: OHMS/WATTS
O-ORANGE Y-YELLOW CAPACITORS:
R-RED N-BROWN MFD/VOLTS
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.
CONNECT BLACK AND WHITE OR BROWN LEADS TO SUPPLY CIRCUIT. CONNECTOR PIN NUMBERS:
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. CONNECTION SHOWN IS FOR 575V OPERATION. EXAMPLE: THIS IS PIN 7
1 2 3 7 0F CONNECTOR J5
REE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.
CONNECT
FOR TH BLACK, RED & WHITE OR BROWN LEADS TO SUPPLY CIRCUIT.
N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6. 8 14 1 2 3 8
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING J5 LATCH
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT VIEW OF CONNECTOR ON PC BOARD
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. ELECTRICAL SYMBOLS PER E1537.
G4365-3
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
WIRING DIAGRAM - INVERTEC V275-S
F-3
207A
202A
D4 310 4 5 324 - Y +
3 J3 R1
307 5 6 B 304A 277
310 4 INPUT J1 W B
313 8 7 375
207A 202A BRIDGE
5 J10
201 A1 308 9 8 303
313 7 _ 309 7 9 377
307 8 204 201 REMOTE
L1 207A 311 10 10 328 POWER
308 2
377
376
375
204 C 11 304
309 6 TP2 W B
375B
- G +
TP3 _F 12 330
SWITCH PC BOARD L2 CONTROL PC BOARD
N.E. 207 1 387
317
318
B E
2 388
TP1
208 4 316 ARC FORCE
L3 209 5 320 ON SMAW
A +D 7 382 B
S4 208 H1B 375B
205 8 383
209 206 203A J2 R2
205 6 229
209 324 304A
1 10 4
R222 J4 11
2 2 303
W221 12 277
304
206
203A
C1 3 76 OFF GTAW
9
327
75
0.6 AMP HOT 328 WELD
SLOW BLOW START MODE
A1 A
H3A
H1A H3A
207
206
380- 220-
202A
H4 H3 W or N L1 F
415V 230V (W) 4 E A 77
H3C 4 8
CR1 A
203A
FAN CR1 440- 2 D B 76
0 1 H6 H5 L2
2 6 575V 460V R (V)
L5 C
REMOTE
N.C. N.A.
202
RECEPTACLE
H1C FAN RELAY 75
B (U) L3
H1D
H3D H1C
S2A S2B G POWER SWITCH
FAN
202
203
203
H1D S1
229
H1 H2 H3 H4 H5 H6 TP6
PRIMARY RECONNECT SWITCHES
(REAR VIEW) TP4 TP5
204 J5 1 6 2 3 4 5 (SHOWN IN 380-575V POSITION)
205
WIRING DIAGRAM- CODES:11267, 11268
C3 C4
H1 H2 H3 H4 H5 H6
C1,C2 SWITCH BOARD CAPACITORS, 2200/500
C3,C4 OUTPUT BY-PASS CAPACITORS, .05/600 320
T2
W221
CR1 FAN RELAY COIL, 12V DC
AUXILIARY
SHUNT
18V
U
W
384 R3
TRANSFORMER
L1,L2 OUTPUT REACTOR W R S5
L3 OUTPUT INDUCTOR (CHOKE) 208
385
387
S3
388
R2 ARC FORCE POTENTIOMETER, 10K/2 W T3 RI
UT G OUTPUT
R3,R4 OUTPUT LOAD RESISTORS, 100/25 I-O HT 318
PR I-IN CHOKE
S1 INPUT POWER SWITCH R T4 PR
INVERTEC V275-S
X4
S2A,S2B RECONNECT SWITCHES 3
S3 OUTPUT RECTIFIER HEATSINK THERMOSTAT C X4 X2
7 SE
S4 SWITCH BOARD HEATSINK THERMOSTAT T L1
205 6 OS X8
S5 CHOKE THERMOSTAT 2 BO
X7
T1 MAIN TRANSFORMER REACTOR X1
T2 AUXILIARY TRANSFORMER UT
201 I-O GND
PR X8
T3,T4 CURRENT TRANSFORMER X1 FROM AMPHENOL
TP1,TP2,TP3 INPUT MOV, 660V AC I-IN CASE
P R
X3 FRONT LINE CORD
GND1
LE
ELECTRICAL DIAGRAMS
T X6
T1 OS CASE
FT
BO B3 BACK
MAIN BASE
B1
TRANSFORMER X7
PROTECTIVE BONDING CIRCUIT
X2
L2 HEAT SINK
X3 OUTPUT RECTIFIER PC BOARD COMPONENT VALUE
X5 LEAD COLORING CODE:
UNITS:
REACTOR X6 B-BLACK U-BLUE RESISTORS:
NOTES: G-GREEN W-WHITE
N.A. MACHINES WITH RED, BLACK AND WHITE OR BROWN POWER CORDS: OHMS/WATTS
O-ORANGE Y-YELLOW CAPACITORS:
R-RED N-BROWN MFD/VOLTS
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.
CONNECT BLACK AND WHITE OR BROWN LEADS TO SUPPLY CIRCUIT. CONNECTOR PIN NUMBERS:
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION. CONNECTION SHOWN IS FOR 575V OPERATION. EXAMPLE: THIS IS PIN 7
1 2 3 7 0F CONNECTOR J5
REE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT
FOR TH BLACK, RED & WHITE OR BROWN LEADS TO SUPPLY CIRCUIT.
N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6. 8 14 1 2 3 8
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING J5 LATCH
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT VIEW OF CONNECTOR ON PC BOARD
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER. ELECTRICAL SYMBOLS PER E1537.
G4365-6
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
DIMENSION PRINT
F-4
3.17 MAX
INVERTEC V275-S
DIAGRAMS
15.89
11.85
.25
O .93
.88
2.08 16.84
O 1.25
7.00 .35 TYP. 20.25 1.44
9.00
A.02
L11981
F-4
NOTES
INVERTEC V275-S
NOTES
INVERTEC V275-S
Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection.
French Ne laissez ni la peau ni des vte- Gardez lcart de tout matriel Protgez vos yeux, vos oreilles et
ments mouills entrer en contact inflammable. votre corps.
ATTENTION avec des pices sous tension.
Isolez-vous du travail et de la terre.
German Berhren Sie keine stromfhrenden Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kr-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Krper oder feuchter Kleidung!
Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
No toque partes eltricas e elec- Mantenha inflamveis bem guarda- Use proteo para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENO da.
Isole-se da pea e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURERS INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYERS 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 UNFALLVERHTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or
Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
Los humos fuera de la zona de res- Spanish
Desconectar el cable de ali- No operar con panel abierto o
piracin.
Mantenga la cabeza fuera de los
mentacin de poder de la mquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilacin o
aspiracin para gases.
PRECAUCION
Gardez la tte lcart des fumes. Dbranchez le courant avant lentre- Noprez pas avec les panneaux French
Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ter les fumes des zones
de travail.
protection enlevs. ATTENTION
Vermeiden Sie das Einatmen von Strom vor Wartungsarbeiten Anlage nie ohne Schutzgehuse German
Schweibrauch! abschalten! (Netzstrom vllig ff- oder Innenschutzverkleidung in
Sorgen Sie fr gute Be- und
Entlftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
Mantenha seu rosto da fumaa. No opere com as tampas removidas. Mantenha-se afastado das partes
Use ventilao e exhausto para Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratria. servio. No opere com os paineis abertos ATENO
No toque as partes eltricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRTICAS DE SEGURANA 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