Lincoln Electric IM803-B User Manual

IM803-B

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RED-D-ARC
ES 275i

For use with machines having Code Numbers:

August, 2006

10994,11166,11223 & 11266

OPERATOR’S MANUAL

Red-D-Arc Spec-Built Welding Equipment

This RED-D-ARC welder is built to RED-D-ARC Extreme Duty
design specifications by Lincoln Electric.

Safety Depends on You

This welder is designed and built with safety in mind.

However, your overall safety can be increased by proper installation

... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT.

And, most importantly, think before you act and be careful.

1-800-245-3660

North America’s Largest Fleet of Welding Equipment

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

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.

AUG 06

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc­tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte­ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se pro­téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma­bles.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please 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_________________________________________________________________________

vv

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions. ..............................................................................................................A-2

Suitable Location..................................................................................................................A-2

Stacking ........................................................................................................................A-2

Tilting.............................................................................................................................A-2

High Frequency Protection............................................................................................A-2

Input Connections ................................................................................................................A-2

Input Fuse and Supply Wire..........................................................................................A-2

Input Supply Connections .............................................................................................A-2

Power Input Connections ..............................................................................................A-2

Input Voltage Reconnect Procedure ....................................................................................A-3

Output Connections..............................................................................................................A-3

Output Cables ...............................................................................................................A-3

________________________________________________________________________________

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-4

Thermal Protection ...............................................................................................................B-4

Fan ......................................................................................................................................B-4

Power-Up Sequence ............................................................................................................B-4

________________________________________________________________________________

vi

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-477 Series

________________________________________________________________________________

A-1

INSTALLATION

Technical Specifications - ES 275i

INPUT AT RATED OUTPUT - THREE PHASE ONLY

INPUT VOLTS-Hz

OUTPUT

CONDITIONS

INPUT

CURRENT

AMPS

Idle

Power

A-1

Efficiency

@ Rated

Output

27/25/13/11
34/33/17/14
38/37/19/16

25/15/15/14/13
32/20/19/18/17

208/230/460/575V - 60Hz.

220/380/400/415/440 - 50Hz

200A@28V.100%

250A@30V. 60%
275A@31V. 35%

200A@28V.100%

250A@30V. 35%

INPUT AT RATED OUTPUT - SINGLE PHASE ONLY

INPUT VOLTS-Hz

208/230/460/575V - 60Hz.

220/380/400/415/440 - 50Hz

OUTPUT

CONDITIONS

200A@28V.100%

250A@30V. 60%

275A@31V.* 35%

200A@28V.100%

250A@30V. 35%

INPUT

CURRENT

AMPS

55/48/26/21
72/62/33/27
80/70/38/31

48/32/30/29/27
63/42/40/38/36

OUTPUT (THREE AND SINGLE PHASE)

WELDING NO LOAD

CURRENT RANGE VOLTAGE

5-275 Amps 70 VDC

RECOMMENDED MINIMUM INPUT WIRE AND FUSE SIZES

THREE PHASE SINGLE PHASE

Input Voltage-Hz

208/230-60
460/575-60

220-50

380/400/415-50

440-50

Cord Size AWG(mm2)

based on a type S, SJ, SJO

or SJT Flexible cord

in 30°C Ambient

8(8.4)

14(2.5)

8(8.4)

12(4)

14(2.5)

Fuse Size

(Time Delay Fuse)

Amps

60
35

60
35
35

Input Voltage-Hz

208-60
230-60

460/575-60

220-50

380/400/415-50

440-50

PHYSICAL DIMENSIONS

Height Width Depth

13.6in.(345mm) - Handle Folded Down 20.25 in.(514mm)

9.0 in.(229mm)

16in.(406mm) - Handle Up

21.7 in.(551)-With Cord Strain Relief

TEMPERATURE RANGES

150W Max

Idle

Power

Efficiency

@ Rated

150W Max

Cord Size AWG(mm2)

based on a type S, SJ, SJO

or SJT Flexible cord

in 30°C Ambient

4 (25)

6(16)

10 (6)

6(16)
8(10)
10(6)

1

1

1

Weight (With Cord)

87%

Output

87%

Fuse Size

(Time Delay Fuse)

Amps

100
100

60

100

60
60

54.5lbs. (24.7Kg)

OPERATING TEMPERATURE RANGE

-20°C to +40°C

(1) When operating on these inputs, the line cord may need to be changed

* On 208VAC single phase the 35% duty cycle output rating is 275A @ 29V.

STORAGE TEMPERATURE RANGE

-40°C to +40°C

ES 275i

A-2

Read this entire installation section before you
start installation.

INSTALLATION

SAFETY PRECAUTIONS

A-2

TILTING

Place the machine directly on a secure, level surface.
The machine may topple over if this procedure is not
followed.

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and
service this equipment.

• Turn the input power off at the
fuse box before working on
equipment.

• Do not touch electrically hot parts.

• Be sure to discharge capacitors with the proce­dure outlined in the Maintenance Section of this
manual before working in that area of the
equipment.

-----------------------------------------------------------------------

SELECT SUITABLE LOCATION

The ES 275i will operate in harsh environments. Even
so, it is important that simple preventative measures
are followed in order to assure long life and reliable
operation.

HIGH FREQUENCY PROTECTION

Locate the ES 275i away from radio controlled
machinery.

CAUTION

The normal operation of the ES 275i may adverse­ly affect the operation of RF controlled equipment,
which may result in bodily injury or damage to the
equipment.

------------------------------------------------------------------------

INPUT CONNECTIONS

The ES 275i should be connected only by a qualified
electrician. Installation should be made in accordance
with all local and national electric codes and the infor­mation detailed below.

INPUT FUSE AND SUPPLY WIRE

Refer to the Technical Specifications page at the
beginning of this chapter for the proper fuse sizes and
supply cable sizes.

• Fuse the input circuit with recommended super lag
fuses or delay type circuit breakers.

• The machine must be located where there is free cir­culation of clean air such that air movement in the
back and out the front will not be restricted.

• Dirt and dust that can be drawn into the machine
should be kept to a minimum. Failure to observe
these precautions can result in excessive operating
temperatures and nuisance shutdown.

• Keep machine dry. Shelter from rain and snow. Do
not place on wet ground or in puddles.

CAUTION

• DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly
under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at
least .06”(1.6mm) thick, which shall extend not
less than 5.90”(150mm) beyond the equipment on
all sides.

-----------------------------------------------------------------------

STACKING

• Install the proper fuse in the fuse holder in the main
disconnect panel.

INPUT SUPPLY CONNECTIONS

Be sure the voltage phase and frequency of the input
power is as specified on the rating plate, located on
the rear of the machine.

Supply line entry provision is in the case rear panel.

POWER INPUT CONNECTION

A 10 ft. power cord is provided and wired into the
machine. Follow the power cord connection instruc­tions. Incorrect connection may result in equipment
damage.

Single Phase Input: Connect green lead to ground
per National Electrical Code. Connect black and white
or brown leads to power. Wrap red lead with tape to
provide 600V insulation.

Three Phase Input: Connect green lead to ground
per National Electrical Code. Connect black, red and
white or brown leads to power.

ES 275i’s cannot be stacked.

ES 275i

A-3

.

.

.

.

Do not touch electrically live parts.

Only qualified persons should install,
use or service this equipment.

RECONNECT PROCEDURE

1. BE SURE POWER SWITCH IS OFF.

208V

220-230V

380-415V

440-460V

575V

'A'

INPUT VOLTAGE RANGE.

removed.

Do not operate with wraparound

inspecting or servicing machine.

Disconnect input power before

IF MACHINE CEASES TO OPERATE (NO METER, NO FAN)

2. CONNECT LEAD 'A' TO DESIRED

3. POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE.

AND THERE IS NO OTHER KNOWN FAILURE: CHECK FUSE;

VOLTAGE=380-575V

VOLTAGE=208-230V

REPLACE WITH SPECIFIED FUSE.

INSTALLATION

A-3

INPUT VOLTAGE RECONNECT
PROCEDURE

When received directly from the factory, units are con­nected for, 460 VAC. If 460 VAC is the desired input,
then the machine may be connected to the power sys­tem without any setup required inside the reconnect
door. For other voltages refer to the instructions locat­ed on the Reconnect Panel Access Door or follow the
instructions below.

CAUTION

Failure to follow these instructions can cause
immediate failure of components within the
welder.

------------------------------------------------------------------------

1. Open the access door on the left side of the
machine.

2. For 208-230: Position the large switch to 208-230.
For 380-575: Position the large switch to 380-575.

OUTPUT CONNECTIONS

Refer to figure B.1 for the location of the 3-Pin
Remote Receptacle and the Output Terminals.

OUTPUT CABLES

Select the output cable size based on Table A.1.

TABLE A.1

Cable Sizes for Combined Length of Electrode and

Work Cable ( Copper Cable Rated at 75°C).

Length Cable Size
up to 150 ft.(46m) 1/0 (50mm
up to 250 ft.(72m) 2/0 (70mm2)

2

)

3. Move the “A” lead to the appropriate terminal.
Refer to figure A.1 below.

Figure A.1 Input Voltage Reconnect Instructions

ES 275i