Lincoln Electric INVERTEC V275-S Service Manual
  1. Manuals
  2. Brands
  3. Lincoln Electric Manuals
  4. Welding System
  5. Invertec V275-S
  6. Service manual
Lincoln Electric INVERTEC V275-S Service Manual

Lincoln Electric INVERTEC V275-S Service Manual

Hide thumbs Also See for INVERTEC V275-S:
Table of Contents

Advertisement

Quick Links

Download this manual
INVERTEC V275-S
For use with machines having Code Numbers:
10993, 11001, 11164, 11165, 11224, 11225, 11267, 11268
SERVICE MANUAL
SVM164-A
| Issue D ate 06, Jan
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.

Advertisement

Table of Contents
loading

Related Manuals for Lincoln Electric INVERTEC V275-S

Summary of Contents for Lincoln Electric INVERTEC V275-S

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. INVERTEC V275-S For use with machines having Code Numbers: 10993, 11001, 11164, 11165, 11224, 11225, 11267, 11268...

  • Page 2: Safety

    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.
  • Page 3 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. electrode work ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety..............................I-IV Installation ..........................Section A Operation..........................Section B Accessories...........................Section C Maintenance .........................Section D Theory of Operation ......................Section E Troubleshooting and Repair....................Section F How to Use Troubleshooting Guide....................F-2 Troubleshooting Guide ........................F-4 Test Procedures ........................F-11 Replacement Procedures ......................F-45 Electrical Diagrams ......................Section G Parts Manual ........................P-476 Series V275-S...
  • Page 7 Section A Section A TABLE OF CONTENTS - INSTALLATION SECTION - Installation ........... Section A Technical Specifications .

  • Page 8: Installation

    INSTALLATION Technical Specifications - Invertec V275-S INPUT AT RATED OUTPUT - THREE PHASE ONLY INPUT VOLTS-Hz INPUT IDLE EFFICIENCY OUTPUT CONDITIONS CURRENT POWER @ RATED OUTPUT AMPS 200A@28V.100% 27/25/13/11 150W Max 208/230/460/575V - 60Hz 250A@30V. 60% 34/33/17/14 275A@31V. 35% 38/37/19/16 25/15/15/14/13 200A@28V.100%...

  • Page 9: Safety Precautions

    • Be sure to discharge capacitors with the proce- dure outlined in the Maintenance Section of this The Invertec V275-S should be connected only by a manual before working in that area of the equip- qualified electrician. Installation should be made in ment.

  • Page 10: Input Voltage Reconnect Procedure

    INSTALLATION 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.

  • Page 11: Output Connections

    INSTALLATION OUTPUT CONNECTIONS QUICK DISCONNECT PLUGS A quick disconnect system is used for the welding Refer to figure A.2 for the location of the 6-Pin Remote cable connections. The welding plug included with the Receptacle and the Output Terminals. machine is designed to accept a welding cable size of FIGURE A.2 OUTPUT CONNECTIONS 1/0 to 2/0.
  • Page 12 NOTES V275-S...
  • Page 13 Section B Section B TABLE OF CONTENTS - OPERATION SECTION - Operation ........... Section B Safety Precautions .

  • Page 14: Operation

    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...
  • Page 15 OPERATION 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. LOCAL REMOTE OUTPUT HOT START ARC FORCE CC STICK REMOTE 1.
  • Page 16 Thermostats are self-resetting once the machine cools suffi- ciently. TIG WELDING* The Invertec V275-S is capable of touch start TIG welding. An electrode cable, work cable, TIG torch, and gas supply with reg- The cooling fan on the V275-S operates once 15 amps of weld- ulator are required.
  • Page 17 Section C Section C TABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ..........Section C Options/Accessories .

  • Page 18: Accessories

    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 connection. sources. This special rack version has all the same Order K960-1 features as the standard V275-S.
  • Page 19 Section D Section D TABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ..........Section D Input Filter Capacitor Discharge Procedure .

  • Page 20: Maintenance

    MAINTENANCE 4. Obtain a high resistance and high wattage resistor WARNING (25-1000 ohms and 25 watts minimum). This resis- ELECTRIC SHOCK can kill. tor is not supplied with machine. NEVER USE A • Have an electrician install and service SHORTING STRAP FOR THIS PROCEDURE. this equipment.
  • Page 21 MAINTENANCE 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).
  • Page 22 MAINTENANCE MAINTENANCE FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. WRAP-AROUND CENTER ASSEMBLY COOLING FANS OUTPUT RECTIFIER ASSEMBLY CASE FRONT ASSEMBLY INPUT RECTIFIER CONTROL PC BOARD CASE BACK ASSEMBLY MAIN TRANSFORMER ASSEMBLY POWER SWITCH OUTPUT TERMINALS CHOKE ASSEMBLY SWITCH BOARD & HEAT SINK ASSEMBLY BASE V275-S...
  • Page 23 Section E-1 Section E-1 TABLE OF CONTENTS -THEORY OF OPERATION SECTION- Theory of Operation ......................Section E General Description ........................E-2 Input Board and Bus Board ......................E-2 Auxiliary Transformer ........................E-2 Main IGBT Switch Board ......................E-3 Main Transformer ........................E-3 Control Board..........................E-4 Fans Circuit ..........................E-4 Output Rectifier...........................E-5 Choke............................E-5 Thermal Protection........................E-6...

  • Page 24: Theory Of Operation

    The input capacitors are charged slow- TRANSFORMER, AND PRECHARGE ly and current limited. An over or under voltage pro- The Invertec V275-S can be connected to a variety of tection circuit located on the switch board monitors three-phase or single-phase input voltages. The initial the capacitor voltages.
  • Page 25 The reverse directions of current flow There is one switch board in the Invertec V275-S. This through the main transformer primaries and the offset board incorporates two input capacitors, two insulat-...
  • Page 26 THEORY OF OPERATION FIGURE E.4 – CONTROL BOARD AND FANS CIRCUIT #1 Primary Current Main Switch Board Feedback Choke Positive Input Switch Input Output To Control & 100A Breaker Terminal Rectifier Board Negative Shunt Output Reconnect Terminal Switch #2 Primary Current Feedback Output...
  • Page 27 THEORY OF OPERATION FIGURE E.5 – OUTPUT RECTIFIER AND CHOKE #1 Primary Current Main Switch Board Feedback Choke Positive Input Switch Input Output To Control & 100A Breaker Rectifier Terminal Board Negative Shunt Output Reconnect Terminal Switch #2 Primary Current Feedback Output Diodes...
  • Page 28 THEORY OF OPERATION THERMAL PROTECTION OVER CURRENT PROTECTION Three normally closed (NC) thermostats protect the The maximum current is 290-300 amps. If reaching V275-S from excessive operating temperatures. that, then the output will be limited to 200 amps until These thermostats are wired in series and are con- the load is removed.
  • Page 29 THEORY OF OPERATION INSULATED GATE BIPOLAR capable of conducting current. A voltage supply con- nected to the drain terminal will allow the IGBT to con- TRANSISTOR (IGBT) duct and supply current to the circuit components OPERATION coupled to the source. Current will flow through the conducting IGBT to downstream components as long as the positive gate signal is present.
  • Page 30 THEORY OF OPERATION Figure E-8 MINIMUM OUTPUT m/sec m/sec MAXIMUM OUTPUT m/sec m/sec PULSE WIDTH MODULATION MAXIMUM OUTPUT By holding the gate signals on for 31 microseconds The term PULSE WIDTH MODULATION is used to and allowing only 2 microseconds of off time during describe how much time is devoted to conduction in the 33 microsecond cycle, the output is maximized.
  • Page 31 Section F-1 Section F-1 TABLE OF CONTENTS TROUBLESHOOTING & REPAIR SECTION Troubleshooting & Repair Section .................Section F How to Use Troubleshooting Guide ..................F-2 PC Board Troubleshooting Procedures and Replacement ..........F-3 Troubleshooting Guide ......................F-4 Test Procedures Input Filter Capacitor Discharge Procedure ..............F-11 Capacitor Balance Test ....................F-13 Main Switch Board Test ....................F-17 Input Rectifier Test ......................F-21...

  • Page 32: Troubleshooting And Repair

    HOW TO USE TROUBLESHOOTING GUIDE CAUTION Service and repair should be performed by only 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.
  • Page 33 Do not touch electrically hot parts. don’t remove them until installation is complete. • If you return a PC Board to The Lincoln Electric Company for credit, it must be in the static-shield- Sometimes machine failures appear to be due to PC ing bag.

  • Page 34: Troubleshooting Guide

    See the Installation Section. C UTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...
  • Page 35 Perform Control Board Tests. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...
  • Page 36 Perform Control Board Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...
  • Page 37 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...
  • Page 38 3. The control board may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...
  • Page 39 CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...
  • Page 40 4. Check for loose or faulty weld- ing cables. CAUTION If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877. V275-S...

  • Page 41: Input Filter Capacitor Discharge Procedure

    INPUT FILTER CAPACITOR DISCHARGE PROCEDURE WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 42 F-12 F-12 TROUBLESHOOTING & REPAIR INPUT FILTER CAPACITOR DISCHARGE PROCEDURE (continued) 4. Obtain a high resistance and high wattage resistor WARNING (25-1000 ohms and 25 watts minimum). This resistor is not with the machine. NEVER USE A ELECTRIC SHOCK SHORTING STRAP FOR THIS PROCEDURE. can kill.

  • Page 43: Capacitor Balance Test

    CAPACITOR BALANCE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.

  • Page 44: Test Procedures

    F-14 F-14 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (continued) FIGURE F.2 - Capacitor Terminal Locations on the Main Switch Board Capacitor (C2) Terminals 202A 207A 203A 206A Capacitor (C1) Terminals TEST PROCEDURE 7. The following tests will be performed with the 1.
  • Page 45 F-15 F-15 TROUBLESHOOTING & REPAIR CAPACITOR BALANCE TEST (continued) 9. Check for the appropriate voltages outlined in 10. If the capacitor voltages are NOT balanced, the Table F.1. capacitors may be in need of “conditioning”. See Maintenance section. NOTE: Voltages may vary with the input line voltage. In the event that the capacitor voltage is too NOTE: The capacitors or other components on the high or too low, the protection circuit will pre-...
  • Page 46 F-16 F-16 NOTES V275-S...

  • Page 47: Main Switch Board Test

    MAIN SWITCH BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 48 F 18 F 18 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST (CONTINUED) Figure F.3 - Main Switch Board Lead location 202A 207A 203A TEST PROCEDURE Main IGBT Resistance Test 1. Remove input power to the V275-S 5. Use a analog volt/ohmmeter check for machine.
  • Page 49 F-19 F-19 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD TEST (CONTINUED) Figure F.4 - Plug J10 Input Signal Test Fault Signal Test 16. Locate leads 311(+) and 313(-) on plug 10. Locate leads 308 and 309 on plug J10. J10. See Wiring Diagram. See Figure F.4. See Wiring Diagram.
  • Page 50 F-20 F-20 NOTES V275-S...

  • Page 51: Input Rectifier Test

    INPUT RECTIFIER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 52 F-22 F-22 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) Figure F.5 - Terminal Schematic TEST PROCEDURE 6. Using a phillips head screwdriver, 1. Remove input power to the V275-S remove leads 207, 207A, and 209 from machine. the input rectifier. 2.
  • Page 53 F-23 F-23 TROUBLESHOOTING & REPAIR INPUT RECTIFIER TEST (CONTINUED) Table F.2 - Input Rectifier Test Points ANALOG METER TEST POINT TERMINALS X10 RANGE + PROBE Acceptable Meter Readings - PROBE Front Terminal 207A Greater than 1000 ohms Front Terminal 207A Greater than 1000 ohms Front Terminal 207A Greater than 1000 ohms...
  • Page 54 F-24 F-24 NOTES V275-S...

  • Page 55: Output Diode Modules Test (Below Code 11250 Only

    (Below code 11250 only) WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 56 F-26 F-26 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) (Below code 11250 only) FIGURE F.7 - Machine Output Terminals Negative Output Positive Output Terminal Terminal TEST PROCEDURE 4. Using the analog ohmmeter test for more 1. Remove input power to the V275-S. than 200 ohms resistance between positive 2.
  • Page 57 F-27 F-27 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) (Below code 11250 only) Figure F.8 - Terminal Probes O F F 5. If 200 ohms is measured then the output 8. Perform Input Filter Capacitor diodes are not “shorted”. Discharge Procedure detailed earlier in this section.
  • Page 58 F-28 F-28 TROUBLESHOOTING & REPAIR OUTPUT DIODE MODULES TEST (continued) (Below code 11250 only) Figure F.9 - Snubber and Output Diode Locations Output Diode Modules 380V 208-230V Snubber Board V275-S...

  • Page 59: Auxiliary Transformer Test

    AUXILIARY TRANSFORMER TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 60 F-30 F-30 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) FIGURE F.10 - Auxiliary Transformer Control Board 380V 208-230V Auxiliary Transformer TEST PROCEDURE 8. Carefully check for the presence of 18VAC 1. Remove input power to the V275-S. at plug J2 pin 1 (lead 387) to pin 2 (lead 388). 2.
  • Page 61 F-31 F-31 TROUBLESHOOTING & REPAIR AUXILIARY TRANSFORMER TEST (continued) FIGURE F.11 - Plug J2 Location on the Control Board Plug J1 Plug J3 Plug J4 Plug J2 FIGURE F.12 - Plug J2 V275-S...
  • Page 62 F-32 F-32 NOTES V275-S...

  • Page 63: Output Current Shunt Test

    OUTPUT CURRENT SHUNT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 64 F-34 F-34 TROUBLESHOOTING AND REPAIR OUTPUT CURRENT SHUNT TEST (continued) FIGURE F.13 - Output Current Shunt Location Output 380V Shunt 208-230V TEST PROCEDURE 9. Carefully measure the voltage drop across the shunt. With a 200 amp load the voltage across 1.
  • Page 65 F-35 F-35 TROUBLESHOOTING AND REPAIR OUTPUT CURRENT SHUNT TEST (continued) Figure F.14 - Control Board Plug J1 Plug J3 Plug J4 Plug J2 Figure F.15 - Plug J4 R222 W221 V275-S...
  • Page 66 F-36 F-36 NOTES V275-S...

  • Page 67: Fan Control And Motor Test

    FAN CONTROL AND MOTOR TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 68 F-38 F-38 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) TEST PROCEDURE 5. Locate plug J2 leads 383+ and 382- on the 1. Using a 5/16” nut driver, remove the case wrap- control board. See Figures F.17 & F.18. around cover.
  • Page 69 F-39 F-39 TROUBLESHOOTING AND REPAIR FAN CONTROL AND MOTOR TEST (continued) FIGURE F.17 - Plug J2 Location on Control Board Plug J1 Plug J3 Plug J4 Plug J2 Figure F.18 - Plug J2 V275-S...
  • Page 70 F-40 F-40 NOTES V275-S...

  • Page 71: Control Board Test

    CONTROL BOARD TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 72 F-42 F-42 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) TEST PROCEDURE 6. Locate plug J10 on the main switch board. See Figure F.19. 1. Remove input power to the V275-S machine. 7. Disconnect plug J10 from the switch board. 2. Using a 5/16” nut driver, remove the case wrap- 8.
  • Page 73 F-43 F-43 TROUBLESHOOTING AND REPAIR CONTROL BOARD TEST (continued) 11. The following checks will verify that the control 14. Check for the presence of 30KHZ from plug board is generating output signals to the J10 pin 2 (Lead 308) to pin 6 (Lead 309). This switch board.
  • Page 74 F-44 F-44 NOTES V275-S...

  • Page 75: Main Switch Board Removal And Replacement

    MAIN SWITCH BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 76 F-46 F-46 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.23 – Main Switch Board Location Main Switch Board PROCEDURE 7. Using a 3/16” allen wrench, remove the four main switch board mounting screws. See 1. Remove input power to the V275-S. Figure F.24.
  • Page 77 F-47 F-47 TROUBLESHOOTING & REPAIR MAIN SWITCH BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.24 - Main Board Plug and Mounting Screw Locations 207A 202A Plug J10 4 Allen Bolts Note:Later design Switch Boards are potted and unserviceable. The removal and replacement proce- dure is still the same.
  • Page 78 F-48 F-48 NOTES V275-S...

  • Page 79: Control Board Removal And Replacement

    CONTROL BOARD REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 80 F-50 F-50 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.25 – Control Board Location Control Board PROCEDURE 4. Locate the control board. See Figure F.25. 1. Remove the input power to the V275-S. 5. Using a phillips head screw driver, remove the four screws from around the two output termi- 2.
  • Page 81 F-51 F-51 TROUBLESHOOTING & REPAIR CONTROL BOARD REMOVAL & REPLACEMENT (continued) FIGURE F.27 - Control Board Plug Location Mounting Bolts Plug J1 Plug J3 Plug J4 Plug J2 Mounting Bolts 7. The previous step will allow you to maneuver 12. Reconnect previously removed plugs. the casefront around to gain better access to the control board.
  • Page 82 F-52 F-52 NOTES V275-S...

  • Page 83: Snubber Board Removal And Replacement

    REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 84 F-54 F-54 TROUBLESHOOTING & REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.28 - Snubber Board Location Snubber Board 380V 208-230V PROCEDURE 6. Disconnect lead 381 and remove snubber 1. Remove input power to the V275-S. board. See Figure F.29. 2.
  • Page 85 F-55 F-55 TROUBLESHOOTING & REPAIR SNUBBER BOARD REMOVAL AND REPLACEMENT (continued) FIGURE F.29 - Snubber Board Nuts V275-S...
  • Page 86 F-56 F-56 NOTES V275-S...

  • Page 87: Output Diodes Removal And Replacement (Below Code 11250 Only

    (Below code 11250 only) WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 88 F-58 F-58 TROUBLESHOOTING & REPAIR OUTPUT DIODES REMOVAL AND REPLACEMENT (continued) (Below code 11250 only) FIGURE F.30 - Output Diode Location Output Diodes 380V 208-230V PROCEDURE 8. Remove the allen bolt located in the center of the output diode using a 9/64” allen wrench. 1.
  • Page 89 F-59 F-59 TROUBLESHOOTING & REPAIR OUTPUT DIODES REMOVAL AND REPLACEMENT (continued) (Below code 11250 only) FIGURE F.31 - Mounting Bolt Locations Mounting Bolts 380V 9/64" 208-230V Allen Bolt 14. Tighten the center allen screw to between 12 and 18 inch pounds. 15.
  • Page 90 F-60 F-60 NOTES V275-S...

  • Page 91: Input Rectifier Removal And Replacement

    INPUT RECTIFIER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 92 F-62 F-62 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) PROCEDURE 3. Perform the Input Filter Capacitor Discharge 1. Remove input power to the V275-S. Procedure detailed earlier in this section. 2. Using a 5/16” nut driver, remove the case wrap- 4.
  • Page 93 F-63 F-63 TROUBLESHOOTING & REPAIR INPUT RECTIFIER REMOVAL AND REPLACEMENT (continued) FIGURE F.33 - Input Rectifier Lead Locations Allen Allen Screw Screw V275-S...
  • Page 94 F-64 F-64 NOTES V275-S...

  • Page 95: Fans Removal And Replacement

    FANS REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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.
  • Page 96 F-66 F-66 TROUBLESHOOTING & REPAIR FANS REMOVAL AND REPLACEMENT (continued) Figure F.34 - Fans Location Fans PROCEDURE 3. Perform the Input Filter Capacitor Discharge 1. Remove input power to the V275-S. Procedure detailed earlier in this section. 2. Using a 5/16” nut driver, remove the case wrap- 4.
  • Page 97 F-67 F-67 TROUBLESHOOTING & REPAIR FANS REMOVAL AND REPLACEMENT (continued) Figure F.35 - Screw Locations Caseback Screws Upper Lower Caseback Screws 5. Using a 5/16” nut driver remove the four case back 8. If the lower fan is to be removed, disconnect leads mounting screws.
  • Page 98 F-68 F-68 TROUBLESHOOTING & REPAIR FANS REMOVAL AND REPLACEMENT (continued) Figure F.36 - Fan Leads Caseback Spacers Fans 11. Replace the four case back mounting screws pre- 12. Replace the case wraparound cover. viously removed. V275-S...

  • Page 99: Retest After Repair

    F-69 F-69 TROUBLESHOOTING RETEST AFTER REPAIR Retest a machine: If it is rejected under test for any reason that require you to remove any part which could affect the machine’s electrical characteristics. If you repair or replace any electrical components: IDLE AMPS Input Volts Idle Watts...
  • Page 100 F-70 F-70 NOTES V275-S...
  • Page 101 ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section ..................Section G Wiring Diagram (Entire Machine) (Code 10993, 11001) .............G-2 Wiring Diagram (Entire Machine) (Code 111164,11165,11224,11225) ........G-3 Wiring Diagram (Entire Machine) (Code 11267,11268)...............G-4 Schematic (Entire Machine) (G4369) (Code 10993, 11001) ............G-5 Schematic (Entire Machine) (G4369-1) (Code 111164,11165,11224,11225).......G-6 Schematic (Entire Machine) (G4369-2) (Code 11267,11268) .............G-7 Control P.C.
  • Page 102 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 10993, 11001 WIRING DIAGRAM - INVERTEC V275-S R(T4) CASE FRONT (REAR VIEW) W(T4) OUTPUT LOCAL R(T3) THERMAL W(T3) 304A INPUT 207A 202A BRIDGE REMOTE 207A CONTROL PC BOARD SWITCH PC BOARD N.E.
  • Page 103 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 11164, 11165, 11224, 11225 WIRING DIAGRAM - INVERTEC V275-S R(T4) CASE FRONT (REAR VIEW) W(T4) OUTPUT LOCAL R(T3) THERMAL W(T3) 304A INPUT 207A 202A BRIDGE POWER REMOTE 207A CONTROL PC BOARD SWITCH PC BOARD N.E.
  • Page 104 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 11267, 11268 WIRING DIAGRAM - INVERTEC V275-S R(T4) CASE FRONT (REAR VIEW) W(T4) OUTPUT LOCAL R(T3) THERMAL W(T3) 304A INPUT 207A 202A BRIDGE REMOTE POWER 207A CONTROL PC BOARD SWITCH PC BOARD N.E.
  • Page 105 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE CODE 10993, 11001 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED FROM X A.01 MANUFACTURER: SWITCH BOARD FUNCTIONAL DESCRIPTION 1. PROVIDING OUTPUT POWER THOUGH Pulse Width Modulation OF THE TWO IGBT MODULES, THE SWITCH BOARD DELIVERS POWER TO RIGHT SIDE, BEHIND CONTROL BOX MOUNTED ON TOP OF C1 &...
  • Page 106 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE CODE 11164,11165,11224,11225 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: SWITCH BOARD FUNCTIONAL DESCRIPTION 1. PROVIDING OUTPUT POWER THOUGH Pulse Width Modulation OF THE TWO IGBT MODULES, THE SWITCH BOARD DELIVERS POWER TO RIGHT SIDE, BEHIND CONTROL BOX MOUNTED ON TOP OF C1 &...
  • Page 107 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE CODE 11267,11268 ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: SWITCH BOARD FUNCTIONAL DESCRIPTION 1. PROVIDING OUTPUT POWER THOUGH Pulse Width Modulation OF THE TWO IGBT MODULES, THE SWITCH BOARD DELIVERS POWER TO RIGHT SIDE, BEHIND CONTROL BOX MOUNTED ON TOP OF C1 &...
  • Page 108 ELECTRICAL DIAGRAMS SCHEMATIC - CONTROL PC BOARD (G4371) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V275-S...
  • Page 109 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 110 G-10 G-10 ELECTRICAL DIAGRAMS SCHEMATIC SWITCH P.C. BOARD (L12016) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V275-S...
  • Page 111 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 112 G-12 G-12 ELECTRICAL DIAGRAMS SCHEMATIC - SNUBBER P.C. BOARD (S24761) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. V275-S...
  • Page 113 Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician.
  • Page 114 Please include the machine’s code number and how the problem was resolved. Thank You, Technical Services Group Lincoln Electric Co. 22801 ST. Clair Ave. Cleveland, Ohio 44117-1199 FAX 216-481-2309 SVM Number ___________________________...

This manual is also suitable for:

109931100111164111651122411225 ... Show all

Table of Contents