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IM802-C
INVERTEC ™ V275-S February, 2011

For use with machines having Code Numbers: 10993, 11001,11164, 11165, 11224
11225, & 11446

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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY 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.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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.

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.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
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,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or can be dangerous.
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep
• DC Manual (Stick) Welder. your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot”. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and within applicable OSHA PEL and
should be as close as possible to the area being welded. ACGIH TLV limits using local exhaust or mechanical
ventilation. In confined spaces or in some circum-
3.e. Ground the work or metal to be welded to a good electrical stances, outdoors, a respirator may be required.
(earth) ground. Additional precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected
damaged insulation. by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
3.g. Never dip the electrode in water for cooling. cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
3.h. Never simultaneously touch electrically “hot” parts of periodically thereafter to be certain it is within applicable
electrode holders connected to two welders because voltage OSHA PEL and ACGIH TLV limits.
between the two can be the total of the open circuit voltage
of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
3.i. When working above floor level, use a safety belt to protect The heat and rays of the arc can react with solvent vapors to
yourself from a fall should you get a shock. form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.j. Also see Items 6.c. and 8.
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.

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 iii
SAFETY
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate cir- Electrical Code, all local codes and the manufacturer’s
cuits. This can create fire hazards or overheat lifting chains recommendations.
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. 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 iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
Pour votre propre protection lire et observer toutes les instruc- zones où lʼon pique le laitier.
tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté 6. Eloigner les matériaux inflammables ou les recouvrir afin de
générales suivantes: prévenir tout risque dʼincendie dû aux étincelles.

Sûreté Pour Soudage A LʼArc 7. Quand on ne soude pas, poser la pince à une endroit isolé de
1. Protegez-vous contre la secousse électrique: la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours 8. Sʼassurer que la masse est connectée le plus prés possible
tout contact entre les parties sous tension et la peau nue de la zone de travail quʼil est pratique de le faire. Si on place
ou les vétements mouillés. Porter des gants secs et sans la masse sur la charpente de la construction ou dʼautres
trous pour isoler les mains. endroits éloignés de la zone de travail, on augmente le risque
b. Faire trés attention de bien sʼisoler 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, câbles de grue, ou autres circuits. Cela peut provoquer
metallique ou des grilles metalliques, principalement dans des risques dʼincendie ou dʼechauffement des chaines et des
les positions assis ou couché pour lesquelles une câbles jusquʼà ce quʼils se rompent.
grande partie du corps peut être en contact avec la
masse. 9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-électrode, la pince de masse, le câble Ceci est particuliérement important pour le soudage de tôles
de soudage et la machine à souder en bon et sûr état galvanisées plombées, ou cadmiées ou tout autre métal qui
defonctionnement. produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir. 10. Ne pas souder en présence de vapeurs de chlore provenant
e. Ne jamais toucher simultanément les parties sous tension dʼopérations de dégraissage, nettoyage ou pistolage. La
des porte-électrodes connectés à deux machines à soud- chaleur ou les rayons de lʼarc peuvent réagir avec les
er parce que la tension entre les deux pinces peut être le vapeurs du solvant pour produire du phosgéne (gas forte-
total de la tension à vide des deux machines. ment toxique) ou autres produits irritants.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions 11. Pour obtenir de plus amples renseignements sur la sûreté,
pour le porte-électrode sʼapplicuent aussi au pistolet de voir le code “Code for safety in welding and cutting” CSA
soudage. Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se pro-

téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de nʼimporte quelle
partie du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
TRANSFORMATEUR ET À
REDRESSEUR
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 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde lʼarc. de lʼélectricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché à
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au 2. Autant que possible, Iʼinstallation et lʼentretien du poste
soudage à lʼaide dʼécrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à lʼinterieur de poste, la
4. Des gouttes de laitier en fusion sont émises de lʼarc de debrancher à lʼinterrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de lʼhuile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
v v

Thank You
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!

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. 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 posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation 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.

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 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
________________________________________________________________________________

Wiring Diagrams and Dimension Print .............................................................Section F

________________________________________________________________________________

Parts Pages ....................................................................................................P-476 Series

________________________________________________________________________________

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% 27/25/13/11 150W Max 87%

208/230/460/575V - 60Hz 250A@30V. 60% 34/33/17/14
275A@31V. 35% 38/37/19/16

200A@28V.100% 25/15/15/14/13
220/380/400/415/440 - 50Hz 32/20/19/18/17
250A@30V. 35%

INPUT AT RATED OUTPUT - SINGLE PHASE ONLY

INPUT VOLTS-Hz OUTPUT INPUT IDLE EFFICIENCY
CONDITIONS CURRENT POWER @ RATED
AMPS OUTPUT

200A@28V.100% 49/48/26/21 150W Max 87%

208/230/460/575V - 60Hz 250A@30V. 60% 63/62/33/27
275A@31V.* 35% 68/67/38/31

200A@28V.100% 48/32/30/29/27
220/380/400/415/440 - 50Hz 63/42/40/38/36
250A@30V. 35%

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 Cord Size AWG(mm2) Fuse Size Input Voltage-Hz Cord Size AWG(mm2) Fuse Size
based on a type S, SJ, SJO (Time Delay Fuse) based on a type S, SJ, SJO (Time Delay Fuse)
or SJT Flexible cord Amps or SJT Flexible cord Amps
in 30°C Ambient in 30°C Ambient
208/230-60 8(8.4) 60 208-60 6(16)1 100
460/575-60 14(2.5) 35 230-60 6 (16)1 100
460/575-60 10 (6) 60
220-50 8(8.4) 60
380/400/415-50 12(4) 35 220-50 6(16)1 100
440-50 14(2.5) 35 380/400/415-50 8(10) 60
440-50 10(6) 60

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
-20°C to +40°C -40°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
A-2 INSTALLATION A-2

Read this entire installation section before you

TILTING
start installation. Place the machine directly on a secure, level surface
or on a recommended undercarriage. The machine
SAFETY PRECAUTIONS may topple over if this procedure is not followed.

WARNING HIGH FREQUENCY PROTECTION

Locate the Invertec V275-S away from radio con-
ELECTRIC SHOCK can kill. trolled machinery.
• Have an electrician install and
service this equipment. CAUTION
The normal operation of the Invertec V275-S may
• Turn the input power off at the adversely affect the operation of RF controlled
fuse box before working on equipment, which may result in bodily injury or
equipment. damage to the equipment.
-----------------------------------------------------------------------
• Do not touch electrically hot parts.
INPUT CONNECTIONS
• Be sure to discharge capacitors with the proce-
dure outlined in the Maintenance Section of The Invertec V275-S should be connected only by a
this manual before working in that area of the qualified electrician. Installation should be made in
equipment. accordance with all local and national electric codes
--------------------------------------------------------------------- and the information detailed below.

SELECT SUITABLE LOCATION INPUT FUSE AND SUPPLY WIRE

Refer to the Technical Specifications page at the
The Invertec V275-S will operate in harsh environ- beginning of this chapter for the proper fuse sizes and
ments. Even so, it is important that simple preventa- supply cable sizes.
tive measures are followed in order to assure long life
and reliable operation. • Fuse the input circuit with recommended super lag
fuses or delay type circuit breakers.
• The machine must be located where there is free cir-
culation of clean air such that air movement in the • Install the proper fuse in the fuse holder in the main
back and out the front will not be restricted. disconnect panel.

• Dirt and dust that can be drawn into the machine

should be kept to a minimum. Failure to observe INPUT SUPPLY CONNECTIONS
these precautions can result in excessive operating Be sure the voltage phase and frequency of the input
temperatures and nuisance shutdown. power is as specified on the rating plate, located on
the rear of the machine.
• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles. Supply line entry provision is in the case rear panel.

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES. POWER INPUT CONNECTION

CAUTION A 10 ft. power cord is provided and wired into the
machine. Follow the power cord connection instruc-
tions. Incorrect connection may result in equipment
Where there is a combustible surface directly damage.
under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at Single Phase Input: Connect green lead to ground
least .06”(1.6mm) thick, which shall extend not per National Electrical Code. Connect black and white
less than 5.90”(150mm) beyond the equipment on or brown leads to power. Wrap red lead with tape to
all sides. provide 600V insulation.
-----------------------------------------------------------------------
STACKING Three Phase Input: Connect green lead to ground
per National Electrical Code. Connect black, red and
V275-Sʼs cannot be stacked. white or brown leads to power.

INVERTEC V275-S
A-3 INSTALLATION A-3

INPUT VOLTAGE RECONNECT

PROCEDURE
When received directly from the factory, units are con-
nected for, 460 VAC. If 460 VAC is the desired input,
then the machine may be connected to the power sys-
tem without any setup required inside the reconnect
door. For other voltages refer to the instructions locat-
ed 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.

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.
THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. A S21230-

VOLTAGE=380-575V VOLTAGE=208-230V

3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.

208V
REPLACE WITH SPECIFIED FUSE.
220-230V AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;

380-415V ' A' IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)

440-460V use or service this equipment.

575V . Only qualified persons should install,
Do not touch electrically live parts.
INPUT VOLTAGE RANGE. removed.
2. CONNECT LEAD 'A' TO DESIRED .. Do not operate with wraparound
1. BE SURE POWER SWITCH IS OFF. inspecting or servicing machine.
. Disconnect input power before
RECONNECT PROCEDURE

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.

380-415V 'A' IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)

220-230V AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;
REPLACE WITH SPECIFIED FUSE.
208V

3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.

VOLTAGE=380-575V VOLTAGE=208-230V

THE LINCOLN ELECTRIC CO. CLEVELAND, OHIO U.S.A. A S21230-

Figure A.1 Input Voltage Reconnect Instructions

INVERTEC V275-S
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.

ON 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.

OFF

BOOT
WELDING CABLE

25 mm
OUTPUT TERMINALS 1 in.
TRIM

REMOTE CONTROL RECEPTACLE

3. Slide the copper tube into the brass plug.
Remote control (K857), Hand amptrol (K963) and
Foot amptrol (K870) connect directly to 6-pin amphe- 4. Insert cable into copper tube.
nol on the front of the unit.
5. Tighten set screw to collapse copper tube. Screw
OUTPUT CABLES must apply pressure against welding cable. The
top of the set screw will be well below the surface
Select the output cable size based on Table A.1. of the brass plug after tightening.
TABLE A.1
Cable Sizes for Combined Length of Electrode and
Work Cable ( Copper Cable Rated at 75°C). SET SCREW

Length Cable Size

up to 150 ft.(46m) 1/0 (50mm2)
up to 250 ft.(72m) 2/0 (70mm2)
BRASS PLUG
COPPER TUBE

6. Slide rubber boot over brass plug. The rubber

boot must be positioned to completely cover all
electrical surfaces after the plug is locked into the
receptacle.

INVERTEC V275-S
B-1 OPERATION B-1

Read and understand this entire section before GENERAL DESCRIPTION

operating your machine.
The Invertec V275-S is a 275 amp arc welding power
SAFETY PRECAUTIONS source that utilizes single or three phase input power,
to produce constant current output. The welding
WARNING response of this Invertec has been optimized for stick
(SMAW) and TIG (GTAW).

ELECTRIC SHOCK can kill.

OPERATIONAL FEATURES
• Do not touch electrically live parts such
The Invertec V275-S provides continuous total range
as output terminals or internal wiring.
output current adjustment, selectable welding modes
• Insulate yourself from the work and and local or remote output control. Welding character-
ground. istics can be controlled via an arc force control.
Additionally, starting characteristics can be adjusted
• Always wear dry insulating gloves. via a “hot start” control.
____________________________________
WELDING CAPABILITY
FUMES AND GASES
can be dangerous.
The Invertec V275-S is rated at 275 amps, 35% duty
cycle (based on a 10 minute cycle). It is also rated at
• Keep your head out of fumes.
200 amps, 100% duty cycle, and 250 amps, 60% duty
cycle.
• Use ventilation or exhaust to
remove fumes from breathing LIMITATIONS
zone.
The V275-S is not recommended for pipe thawing.
____________________________________
WELDING, CUTTING and
GOUGING SPARKS
can cause fire or explosion

• 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 equip-

ment. Observe all safety information throughout this
manual.

INVERTEC V275-S
 B-2 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 corre-
sponding explanations.

FIGURE B.1 — CASE FRONT CONTROLS.

2
8

3
LOCAL
10
REMOTE OUTPUT
HOT START
4 CC STICK ARC FORCE
ON 5

-10 +10 OFF

TIG
6
REMOTE
9
ON
1

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

3. LOCAL/REMOTE SWITCH - Place in the SMAW LOCAL & REMOTE ENERGIZED

“LOCAL” position to allow output adjustment at the
OFF
machine. Place in the “REMOTE” position to allow output 5. HOT START - Controls the amount of starting ener-
adjustment at remote pot or amptrol. In Remote, the
gy in CC Stick (SMAW). The Hot Start can be either
machine output control pot is the limit setting for remote
turned on or off. When on, it provides a striking current at
control.
160% of the set current or 275A whichever is larger then
quickly reverts to the set current in 0.4 second.
4. MODE SWITCH
CC -Stick (SMAW) Use this mode for all stick welding.
Output energized when machine is on.

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 machineʼs protection circuitry activated.
mum settings. Full range is from -10(Soft) to +10(Crisp) Turn the output control down to correct this condition.

7. OUTPUT TERMINALS - These quick disconnect termi- PARALLEL OPERATION

nals provide connection points for the electrode and work The Invertecʼs are operable in parallel. For best results, the cur-
cables. Refer to Output Connection in the Installation chap- rents of each machine should be reasonably well shared. As an
ter for proper cable sizes. For positive polarity welding con- example, with two machines set up in parallel for a 300 amp
nect the electrode cable to the positive terminal and the work procedure, each machine should be set to deliver approximately
cable to the negative terminal. To weld negative polarity 150 amps, not 200 amps from one and 100 amps from the
reverse the electrode and work cables. other. This will minimize nuisance feedback conditions. In gen-
eral, more than two machines in parallel will not be effective due
8. THERMAL SHUTDOWN INDICATOR - This light will to the voltage requirements of procedures in that power range.
illuminate if an internal thermostat has been activated.
Machine output will return after the internal components To set machine outputs, start with output control pots and arc
have returned to a normal operating temperature. See force pots in identical positions. Adjust outputs and arc forces to
Thermal Protection later in this Operation chapter. maintain current sharing while establishing the proper output
current.
9. 6-PIN REMOTE RECEPTACLE
(Refer to Output Connection in the Installation chapter.) OVERLOAD PROTECTION
The machine is electrically protected from producing high output
10. POWER LIGHT - This Light will illuminate when the currents. Should the output current exceed 300A, an electronic
power switch is in the “ON” position. protection circuit will reduce the current to less than 200A. The
machine will continue to produce this low current until the pro-
CONSTANT CURRENT PROCESSES tection circuit is reset. Reset occurs when the output load is
removed.
MANUAL ARC WELDING (STICK)*
Note: When TIG welding with the Output Knob at or above 275
The Invertec may be utilized as a manual DC arc welder with
Amps the Arc may go out.
the electrode cable, work cable, and electrode holder being the
only equipment required.
THERMAL PROTECTION
AIR CARBON ARC CUTTING* Thermostats protect the machine from excessive operating tem-
Air carbon arc cutting may be performed with the Invertec within peratures. Excessive temperatures may be caused by a lack of
cooling air or operating the machine beyond the duty cycle and
its output rating using 3/16” diameter carbon rods. Output
output rating. If excessive operating temperature should occur,
cables, an air carbon arc electrode cable assembly, and a
the thermostats will prevent output voltage or current.
source of compressed air are required.
Thermostats are self-resetting once the machine cools suffi-
TIG WELDING* ciently.
The Invertec V275-S is capable of touch start TIG welding. An
electrode cable, work cable, TIG torch, and gas supply with reg- FAN
ulator are required. Refer to Accessories section of this manu- The cooling fan on the V275-S operates once 15 amps of weld-
al. ing current is drawn and for 7 minutes after the output current
Touch starting is done as follows: has stopped flowing.
1. Place the shield cup edge on the work piece.
2. Rock the tungsten down to touch. The fan will also run anytime the machine has over heated.
3. Trigger the output, if using remote control.
4. Gently rock back the tungsten from the workpiece. POWER-UP SEQUENCE
At power up the thermal light (and Power light on codes 11164
Note: The short circuit current is limited to 20 amps to aid in and above) turns on and the fans run for approximately 3 sec-
touch starting. Panel output control becomes the current onds. This is the pre-charge time for the main capacitors. After
limit setting when in remote control. 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 TIG OPTIONS 

Hand Amptrol - may be used in place of the Foot

REMOTE OUTPUT CONTROL - Consists of a control
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- K2269-1, V275-S Includes:

ing cable to Twist-Mate cable plug. For 1/0-2/0 (50-
70mm2) cable. • V-275-S
Order K1759-70 • Twist-Mate Cable Plugs (K852-70), qty 2

Twist-Mate Cable Receptacle - For connecting weld- V275-S 4-Pack and 8-Pack Inverter Racks 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
Twist-Mate Plugs and Receptacles are not used sources in an industrially designed portable pack-
with Code 11446. age. Entire system meets National Electric Code
(NEC) standards.
TIG OPTIONS
• Includes 4 or 8 Invertec V275-S rack model power
Twist-Mate Torch Adapter - For connection of PTA-9 sources. This special rack version has all the same
or PTA-17V torches (1 piece cable) to power sources features as the standard V275-S.
without as passing through the Twist-Mate connec-
tion.
Order K960-1

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

4. Obtain a high resistance and high wattage resistor

WARNING (25-1000 ohms and 25 watts minimum). This resis-
ELECTRIC SHOCK can kill. tor is not supplied with machine. NEVER USE A
• Have an electrician install and service SHORTING STRAP FOR THIS PROCEDURE.
this equipment.
• Turn the input power off at the fuse
5. Locate the four capacitor terminals (large hex head
box before working on equipment.
cap screws) shown in Figure D.1. One pair at the
• Do not touch electrically hot parts.
• Prior to Performing preventative main- top and one pair at the bottom of the Power Board.
tenance, perform the following capaci-
tor discharge procedure to avoid elec- 6. Use electrically insulated gloves and insulated pli-
tric shock. ers. Hold body of the resistor and connect resistor
--------------------------------------------------------------------- leads across the two capacitor terminals. Hold
resistor in place for 10 seconds. DO NOT TOUCH
INPUT FILTER CAPACITOR CAPACITOR TERMINALS WITH YOUR BARE
DISCHARGE PROCEDURE HANDS.

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.

FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.

POWER UPPER
BOARD CAPACITOR TERMINALS

LOWER
CAPACITOR
TERMINALS

POWER
RESISTOR

RIGHT SIDE OF MACHINE INSULATED

PLIERS

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.

2. Remove the machine wrap-around cover and per-

form the input filter capacitor discharge procedure
(detail at the beginning of this chapter).

3. Keeping the machine clean will result in cooler

operation and higher reliability. Be sure to clean the
following areas with a low pressure air stream. See
figure D.2 for component locations.

•Power and control printed circuit boards

•Power switch

•Main transformer

•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 break-

age. Repair the case as required. Keep the case in
good condition to ensure that high voltage parts are
protected and correct spacings are maintained. All
external sheet metal screws must be in place to
assure case strength and electrical ground continu-
ity.

6. Check electrical ground continuity. Using an ohm-

meter, measure resistance between either output
terminal and an unpainted surface of the machine
case. (See Figure D.2 for locations.) Meter reading
should be 500,000 ohms or more. If meter reading
is less than 500,000 ohms, check for electrical com-
ponents that are not properly insulated from the
case. Correct insulation if needed.

7. Replace machine cover and screws.

INVERTEC V275-S
D-3 MAINTENANCE D-3

FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.

WRAP-AROUND

CENTER ASSEMBLY

OUTPUT COOLING FANS

RECTIFIER
ASSEMBLY

CASE FRONT ASSEMBLY

INPUT
CONTROL PC BOARD RECTIFIER

CASE BACK ASSEMBLY

MAIN TRANSFORMER ASSEMBLY

POWER SWITCH
OUTPUT TERMINALS

CHOKE ASSEMBLY SWITCH BOARD &

HEAT SINK ASSEMBLY

BASE

INVERTEC V275-S
E-1 TROUBLESHOOTING E-1

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.
__________________________________________________________________________
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.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

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

PC BOARD TROUBLESHOOTING PROCEDURES

WARNING - Remove the P.C. Board from the static-
shielding bag and place it directly into the
ELECTRIC SHOCK can kill. equipment. Donʼt set the P.C. Board on or
Have an electrician install near paper, plastic or cloth which could have
and service this equip- a static charge. If the P.C. Board canʼt be
ment. Turn the input power installed immediately, put it back in the static-
OFF at the fuse box before shielding bag.
working on equipment. Do
not touch electrically hot - If the P.C. Board uses protective shorting
parts. jumpers, donʼt remove them until installation
_______________________________ is complete.
CAUTION: Sometimes machine failures
appear to be due to PC board failures. These - If you return a P.C. Board to The Lincoln
problems can sometimes be traced to poor Electric Company for credit, it must be in the
electrical connections. To avoid problems static-shielding bag. This will prevent further
when troubleshooting and replacing PC damage and allow proper failure analysis.
boards, please use the following procedure:
4. Test the machine to determine if the fail-
1. Determine to the best of your technical ure symptom has been corrected by the
ability that the PC board is the most likely replacement PC board.
component causing the failure symptom.
NOTE: It is desirable to have a spare (known
2. Check for loose connections at the PC good) PC board available for PC board trou-
board to assure that the PC board is prop- bleshooting.
erly connected.
NOTE: Allow the machine to heat up so that
3. If the problem persists, replace the sus- all electrical components can reach their oper-
pect PC board using standard practices to ating temperature.
avoid static electrical damage and electri-
cal shock. Read the warning inside the 5. Remove the replacement PC board and
static resistant bag and perform the follow- substitute it with the original PC board to
ing procedures: recreate the original problem.

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 bodyʼs 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 donʼt 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

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage
is observed when cover wrap-around
is removed.

The machine is dead - no output. 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 single-

phase operation, inspect to
assure that the WHITE and
BLACK leads are connected
properly and the RED lead is not
connected and is insulated.

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.

5. Check continuity of the 0.6-amp

slow blow fuse located on the
reconnect panel.

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.

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, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.

INVERTEC V275-S
E-4 TROUBLESHOOTING E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS

Output turns on momentarily, then 1. Check the input voltages and

switches off and repeats cycle. reconnection procedures. Make
sure the input voltage is correct
for the machine. See Input
Voltage Reconnect Procedure.

2. Check or replace remote control

device. (If used)

If all recommended possible areas of

misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Remote output control not 1. Make sure the Local/Remote Service Facility.
functioning. The machine operates switch (S3) is in the REMOTE
normally on LOCAL control. position.

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, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.

INVERTEC V275-S
E-5 TROUBLESHOOTING E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS

No output - Main input fuses open, 1. Inspect input leads for possible
indicating excessive current draw. shorts or grounds or mis-connec-
tions.

2. Install new fuses and reapply

power. If fuses open again, con-
sult a Lincoln Authorized Field
Service Facility.

If all recommended possible areas of

misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
The machine operates normally 1. Check the input voltage and input Service Facility.
when connected for 200 - 230VAC voltage reconnect procedures.
input. There is no output when the See Installation Section of this
machine is connected to 380VAC or manual.
higher.

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

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
OUTPUT PROBLEMS

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.

3. Check for loose or faulty welding

cables.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, con-
tact your local authorized field service facility for technical troubleshooting assistance before you proceed.

INVERTEC V275-S
E-7 TROUBLESHOOTING E-7

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
WELDING PROBLEMS

Poor welding, weld settings drift, or 1. Make sure the machine settings
output power is low. 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. If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized Field
Poor stick electrode welding 1. Check for loose or faulty welding Service Facility.
performance. The arc pops out. cables.

2. Is the electrode DRY? Try weld-

ing 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.

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
WIRING DIAGRAM- CODES: 10993, 11001

INVERTEC V275-S
DIAGRAMS
ENHANCED DIAGRAM

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
F-1

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

INVERTEC V275-S
ELECTRICAL DIAGRAMS
WIRING DIAGRAM- CODES: 11164, 11165, 11224, 11225, 11446
ENHANCED DIAGRAM

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
 F-3
WIRING DIAGRAM- CODES:11267, 11268

INVERTEC V275-S
ELECTRICAL DIAGRAMS

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

4.30 MAX .79 MIN

RECONNECT DOOR
OPEN

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
 • Do not touch electrically live parts or • Keep flammable materials away. • Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

• Insulate yourself from work and
ground.
Spanish
• No toque las partes o los electrodos • Mantenga el material combustible • Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION • Aislese del trabajo y de la tierra.

French • Ne laissez ni la peau ni des vête- • Gardez à l’écart de tout matériel • Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
• Isolez-vous du travail et de la terre.

German • Berühren Sie keine stromführenden • Entfernen Sie brennbarres Material! • Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
• Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
• Não toque partes elétricas e electro- • Mantenha inflamáveis bem guarda- • Use proteção para a vista, ouvido e
dos com a pele ou roupa molhada. dos. corpo.
ATENÇÃO • Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

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 ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN 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
piración.
• Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
• Gardez la tête à l’écart des fumées. • Débranchez le courant avant l’entre- • N’opérez pas avec les panneaux French
• Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
• Vermeiden Sie das Einatmen von • Strom vor Wartungsarbeiten • Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öffnen; oder Innenschutzverkleidung in
• Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Maschine anhalten!) Betrieb setzen! WARNUNG
• Não opere com as tampas removidas. Portuguese
• Mantenha seu rosto da fumaça. • Mantenha-se afastado das partes
• Use ventilação e exhaustão para • Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço.
• Não toque as partes elétricas nuas.
• Não opere com os paineis abertos ATENÇÃO
ou guardas removidas.

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 •
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com