Red-D-Arc IM803-B, ES 275i Operator's Manual

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IM803-B

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

SAFETY

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.

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

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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.

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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.

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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.

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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.

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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

SAFETY

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

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

SAFETY

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_________________________________________________________________________

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.

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

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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

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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

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Troubleshooting .................................................................................................Section E

Safety Precautions.................................................................................................E-1

PC Board Troubleshooting Procedures.................................................................E-2

Troubleshooting Guide.............................................................................E-3 thru E-7

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

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Parts Pages ....................................................................................................P-477 Series

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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)

Weight (With Cord)

87%

Output

87%

Fuse Size

(Time Delay Fuse)

Amps

100 100

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.

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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.

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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.

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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)

)

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

Figure A.1 Input Voltage Reconnect Instructions

ES 275i

B-1

OPERATION

B-1

Read and understand this entire section before operating your machine.

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

____________________________________

FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

____________________________________

WELDING, CUTTING and GOUGING SPARKS can cause fire or explosion

GENERAL DESCRIPTION

The ES 275i is a 275 amp arc welding power source that utilizes single or three phase input power, to produce constant current output. The welding response of this Invertec has been optimized for stick (SMAW) and TIG (GTAW).

OPERATIONAL FEATURES

The ES 275i provides continuous total range output current adjustment, selectable welding modes and local or remote output control. Welding characteristics can be controlled via an arc force control. Additionally, starting characteristics can be adjusted via a “hot start” control.

WELDING CAPABILITY

The ES 275i is rated at 275 amps, 35% duty cycle (based on a 10 minute cycle). It is also rated at 200 amps, 100% duty cycle, and 250 amps, 60% duty cycle.

LIMITATIONS

The ES 275i is not recommended for pipe thawing.

• Keep flammable material away.

• Do not weld, cut or gouge on containers that have held combustibles.

____________________________________

ARC RAYS can burn.

• Wear eye, ear and body protection.

____________________________________

Only qualified personnel should operate this equipment. Observe all safety information throughout this manual.

ES 275i

B-2

LOCAL

REMOTE

ARC FORCE

HOT START

-10

+10

OUTPUT

CC STICK

TIG

OFF

OPERATION

B-2

CONTROLS AND SETTINGS

All operator controls and adjustments are located on the case front of the ES 275i. Refer to Figure B.1 and corresponding explanations.

FIGURE B.1 — CASE FRONT CONTROLS.

1. POWER SWITCH - Place the lever in the “ON”

position to energize the machine. When the power is on the output will be energized in STICK (SMAW) mode and TIG (GTAW) if the remote is set to local control. At power up the thermal Light and Fan will turn on for approximately 3 seconds.

2. OUTPUT CONTROL - This controls the output

current. Control is provided over the entire output range of the power source with (1) turn of the control knob. This control may be adjusted while under load to change power source output. When using remote control this function becomes the limit setting.

3. LOCAL/REMOTE SWITCH - Place in the

“LOCAL” position to allow output adjustment at the machine. Place in the “REMOTE” position to allow output adjustment at remote pot or amptrol. In Remote, the machine output control pot is the limit setting for remote control.

4. MODE SWITCH

CC -Stick (SMAW) Use this mode for all stick welding. Output energized when machine is on.

TIG (GTAW) Optimized for touch start use. Short circuit current is limited to approximately 20 amps to aid in touch starting.

5. HOT START - Controls the amount of starting ener-

gy in CC Stick (SMAW). The Hot Start can be either turned on or off. When on, it provides a striking current at 260% of the set current or 275A whichever is larger then quickly reverts to the set current in 0.4 second.

6. ARC FORCE - This control functions in CC Stick

(SMAW) modes to adjust the Arc Force. The arc is soft at the minimum settings and more forceful or driving at the maximum settings. Higher spatter levels may be present at the maximum settings.

Full range is from -10(Soft) to +10(Crisp)

ES 275i

B-3

OPERATION

7. OUTPUT TERMINALS - These quick discon-

nect terminals are compatible with TWECO®* con- nectors. The terminal provide connection points for the electrode and work cables. Refer to Output Connection in the Installation chapter for proper cable sizes. For positive polarity welding connect the electrode cable to the positive terminal and the work cable to the negative terminal. To weld negative polarity reverse the electrode and work cables.

* TWECO® is registered trademark of Thermo Dyne Corporation.

8. THERMAL SHUTDOWN INDICATOR -

This light will illuminate if an internal thermostat has been activated. Machine output will return after the internal components have returned to a normal operating temperature. See Thermal Protection later in this Operation chapter.

9. 3-PIN REMOTE RECEPTACLE

3-Pin remote control allows for remote control of the Output current.

10. POWER LIGHT - This Light will illuminate

when the power switch is in the “ON” Position.

CONSTANT CURRENT PROCESSES

STICK WELDING*

The Invertec may be utilized as a manual DC arc welder with the electrode cable, work cable, and electrode holder being the only equipment required.

B-3

Note: The short circuit current is limited to 20 amps to

aid in touch starting. Panel output control becomes the current limit setting when in remote control.

*Note: Operating this machine with the output control

set to maximum may cause the machine to phase back and the arc to go out. This occurs because the welding current exceeded 300 amps and the machine’s protection circuitry activated. Turn the output control down to correct this condition.

PARALLEL OPERATION

The Invertec’s are operable in parallel. For best results, the currents of each machine should be reasonably well shared. As an example, with two machines set up in parallel for a 300 amp procedure, each machine should be set to deliver approximately 150 amps, not 200 amps from one and 100 amps from the other. This will minimize nuisance feedback conditions. In general, more than two machines in parallel will not be effective due to the voltage requirements of procedures in that power range.

To set machine outputs, start with output control pots and arc force pots in identical positions. Adjust outputs and arc forces to maintain current sharing while establishing the proper output current.

AIR CARBON ARC CUTTING*

Air carbon arc cutting may be performed with the Invertec within its output rating using 3/16”(4.8mm) diameter carbon rods. Output cables, an air carbon arc electrode cable assembly, and a source of compressed air are required.

TIG WELDING*

The ES 275i is capable of touch start TIG welding. An electrode cable, work cable, TIG torch, and gas supply with regulator are required.

Touch starting is done as follows:

1. Place the shield cup edge on the work piece.

2. Rock the tungsten down to touch.

3. Gently rock back the tungsten from the workpiece.

ES 275i

B-4

OPERATION

OVERLOAD PROTECTION

The machine is electrically protected from producing high output currents. Should the output current exceed 300A, an electronic protection circuit will reduce the current to less than 200A. The machine will continue to produce this low current until the protection circuit is reset. Reset occurs when the output load is removed.

Note: When TIG welding with the Output Knob at or above 275 Amps the Arc may go out.

THERMAL PROTECTION

Thermostats protect the machine from excessive operating temperatures. Excessive temperatures may be caused by a lack of cooling air or operating the machine beyond the duty cycle and output rating. If excessive operating temperature should occur, the thermostats will prevent output voltage or current.

Thermostats are self-resetting once the machine cools sufficiently.

B-4

FAN

The cooling fan on the ES 275i operates once 15 amps of welding current is drawn and for 7 minutes after the output current has stopped flowing.

The fan will also run anytime the machine has over heated.

POWER-UP SEQUENCE

At power up the thermal light (and Power light on codes 11164 and above) turns on and the fans run for approximately 3 seconds. This is the pre-charge time for the main capacitors. After this time the fans and thermal light turn off and the pre-charge relay closes to apply full line power to the capacitors. At this time the machine is ready to weld.

ES 275i

D-1

UPPER

CAP ACIT OR TERMINALS

LOWER

CAPACITOR

TERMINALS

INSULATED

GLOVES

INSULATED

PLIERS

POWER

RESISTOR

POWER

BOARD

RIGHT SIDE OF MACHINE

MAINTENANCE

D-1

WARNING

ELECTRIC SHOCK can kill.

• Have an electrician install and service this equipment.

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

• Do not touch electrically hot parts.

• Prior to Performing preventative main-

tenance, perform the following capacitor discharge procedure to avoid electric shock.

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

INPUT FILTER CAPACITOR DISCHARGE PROCEDURE

1. Turn off input power or disconnect input power lines.

2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-around machine cover.

3. Be careful not to make contact with the capacitor terminals that are located in the top and bottom of the Power Board.

4. Obtain a high resistance and high wattage resistor (25-1000 ohms and 25 watts minimum). This resistor is not supplied with machine. NEVER USE A SHORTING STRAP FOR THIS PROCEDURE.

5. Locate the four capacitor terminals (large hex head cap screws) shown in Figure D.1. One pair at the top and one pair at the bottom of the Power Board.

6. Use electrically insulated gloves and insulated pliers. Hold body of the resistor and connect resistor leads across the two capacitor terminals. Hold resistor in place for 10 seconds. DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS.

7. Repeat discharge procedure for the capacitor on

other two terminals.

8. Check voltage across terminals of all capacitors with a DC voltmeter. Polarity of capacitor terminals is marked on PC board above terminals. Voltage should be zero. If any voltage remains, repeat this capacitor discharge procedure.

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

ES 275i

D-2

MAINTENANCE

ROUTINE MAINTENANCE

1. Perform the following preventive maintenance procedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best.

2. Remove the machine wrap-around cover and perform the input filter capacitor discharge procedure (detail at the beginning of this chapter).

3. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean the following areas with a low pressure air stream. See figure D.2 for component locations.

•Power and control printed circuit boards

•Power switch

•Main transformer

D-2

•Input rectifier

•Heat sink fins

•Input Filter Capacitors

•Output Terminals

4. Examine capacitors for leakage or oozing. Replace if needed.

5. Examine the sheet metal case for dents or breakage. Repair the case as required. Keep the case in good condition to ensure that high voltage parts are protected and correct spacings are maintained. All external sheet metal screws must be in place to assure case strength and electrical ground continuity.

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

7. Replace machine cover and screws.

ES 275i

D-3

SWITCH BOARD & HEAT SINK ASSEMBLY

CONTROL PC BOARD

MAIN TRANSFORMER ASSEMBLY

CHOKE ASSEMBL Y

OUTPUT TERMINALS

POWER SWITCH

CENTER ASSEMBL Y

COOLING FANS

CASE BACK ASSEMBLY

CASE FRONT ASSEMBLY

WRAP-AROUND

BASE

INPUT RECTIFIER

OUTPUT RECTIFIER ASSEMBLY

MAINTENANCE

FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.

D-3

ES 275i

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

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

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

ES 275i

E-2

TROUBLESHOOTING & REPAIR

PC BOARD TROUBLESHOOTING PROCEDURES

E-2

WARNING

ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. Turn the input power OFF at the fuse box before working on equipment. Do not touch electrically hot parts.

_______________________________

CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure:

1. Determine to the best of your technical ability that the PC board is the most likely component causing the failure symptom.

2. Check for loose connections at the PC board to assure that the PC board is properly connected.

3. If the problem persists, replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock. Read the warning inside the static resistant bag and perform the following procedures:

- Remove the P.C. Board from the staticshielding bag and place it directly into the equipment. Don’t set the P.C. Board on or near paper, plastic or cloth which could have a static charge. If the P.C. Board can’t be installed immediately, put it back in the staticshielding bag.

- If the P.C. Board uses protective shorting jumpers, don’t remove them until installation is complete.

- If you return a P.C. Board for credit, it must be in the static-shielding bag. This will prevent further damage and allow proper failure analysis.

4. Test the machine to determine if the failure symptom has been corrected by the replacement PC board.

NOTE: It is desirable to have a spare (known good) PC board available for PC board troubleshooting.

NOTE: Allow the machine to heat up so that all electrical components can reach their operating temperature.

5. Remove the replacement PC board and substitute it with the original PC board to recreate the original problem.

P.C. Board can be damaged by static electricity.

- Remove your body’s static charge before opening

ATTENTION Static-Sensitive Devices Handle only at Static-Safe Workstations

Reusable Container Do Not Destroy

equipment frame. Keep touching the frame to prevent static build-up. Be sure not to touch any electrically live parts at the same time.

- Tools which come in contact with the P.C. Board must be either conductive, anti-static or static-dissipate.

the static-shielding bag. Wear an anti-static wrist strap. For safety, use a 1 Meg ohm resistive cord connected to a grounded part of the equipment frame.

- If you don’t have a wrist strap, touch an unpainted, grounded, part of the

a. If the original problem does not reap-

pear by substituting the original board, then the PC board was not the problem. Continue to look for bad connections in the control wiring harness, junction blocks, and terminal strips.

b. If the original problem is recreated by

the substitution of the original board, then the PC board was the problem. Reinstall the replacement PC board and test the machine.

6. Always indicate that this procedure was followed when warranty reports are to be submitted.

NOTE: Following this procedure and writing on the warranty report, “INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM,” will help avoid denial of legitimate PC board warranty claims.

ES 275i

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Major physical or electrical damage is observed when cover wrap-around is removed.

The machine is dead - no output.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. The input power switch must be in the ON position.

2. Make sure the input voltage is correct for the machine.

3. If the machine is set for singlephase operation, inspect to assure that the WHITE and BLACK leads are connected properly and the RED lead is not connected and is insulated.

4. Check that the input voltage setup switch and jumper “A” (the reconnect auxiliary jumper) are in the proper position for the input voltage being applied. Refer to

Input Voltage Reconnect Procedure in the Installation

Chapter.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Authorized Field Service Facility.

5. Check continuity of the 0.6-amp slow blow fuse located on the reconnect panel.

No output but the fan operates normally.

1. If the machine has not been used for a long time and is connected for 380 VAC or higher, the capacitors may need “conditioning”. See Input Filter Capacitor Conditioning.

2. The machine may be overheated. Check the thermal indicator light. Wait for the machine to cool and the thermostats to reset.

CAUTION

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

ES 275i

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Output turns on momentarily, then switches off and repeats cycle.

Remote output control not functioning. The machine operates normally on LOCAL control.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Check the input voltages and reconnection procedures. Make sure the input voltage is correct for the machine. See Input Voltage Reconnect Procedure.

2. Check or replace remote control device. (If used)

1. Make sure the Local/Remote switch (S3) is in the REMOTE position.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Authorized Field Service Facility.

2. The remote control device may be faulty. Replace.

3. The Local/Remote switch must be in the LOCAL position unless a remote control device is attached to the remote receptacle.

CAUTION

ES 275i

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

(SYMPTOMS)

No output - Main input fuses open, indicating excessive current draw.

The machine operates normally when connected for 200 - 230VAC input. There is no output when the machine is connected to 380VAC or higher.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. Inspect input leads for possible shorts or grounds or mis-connections.

2. Install new fuses and reapply power. If fuses open again, consult a Authorized Field Service Facility.

1. Check the input voltage and input voltage reconnect procedures. See Installation Section of this manual.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Authorized Field Service Facility.

CAUTION

ES 275i

E-6

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-6

PROBLEMS

(SYMPTOMS)

The machine will not produce more than 200 amps.

POSSIBLE

CAUSE

OUTPUT PROBLEMS

1. This may be normal operation. If the output current exceeds 300 amps, an electronic protection circuit will reduce the current to less than 200 amps. The machine will continue to produce this low current until the protection circuit is reset. Reset occurs when the output load is removed.

2. Check the input voltage and input voltage reconnect procedures. See Input Voltage Reconnect

Procedure.

3. Check for loose or faulty welding cables.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Authorized Field Service Facility.

CAUTION

ES 275i

E-7

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-7

PROBLEMS

(SYMPTOMS)

Poor welding, weld settings drift, or output power is low.

Poor stick electrode welding performance. The arc pops out.

POSSIBLE

CAUSE

WELDING PROBLEMS

1. Make sure the machine settings are correct for the weld process being used.

2. Check machine performance on LOCAL control. If OK then the remote control device may be faulty. Check or replace.

3. Check the input voltages and input voltage reconnect procedures. See Installation Section of this manual.

4. Check for loose or faulty welding cables.

1. Check for loose or faulty welding cables.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Authorized Field Service Facility.

The thermal light and fan keep turning on and off.

2. Is the electrode DRY? Try welding with another electrode from a different container. Make sure you have the correct electrode for the application.

3. Make sure the machine settings are correct for the weld process being used.

1. Check the input voltage section.

2. Check for blockage of vents,

which restricts air flow into or out of the machine.

CAUTION

ES 275i

F-1

ARC FORCE

WELD

MODE

OFF

328

327

304

SMAW

GTAW

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.

OHMS/WATTS

COMPONENT VALUE

UNITS:

RESISTORS:

MFD/VOLTS

CAPACITORS:

LATCH

0F CONNECTOR J5

EXAMPLE: THIS IS PIN 7

LEAD COLORING CODE:

B-BLACK

G-GREEN

O-ORANGE

R-RED

CONNECTOR PIN NUMBERS:

U-BLUE

Y-YELLOW

W-WHITE

G4365-2

WIRING DIAGRAM - RED-D-ARC ES275i

HOT

START

THERMAL

PRI

-O

-I

TP1

INPUT

BRIDGE

POWER SWITCH

OUTPUT

376

375

377

TP2

TP3

380-

415V

575V

220-

230V

440-

460V

208V

0.6 AMP SLOW BLOW

RI-

-OUT

BASE

CASE

FRONT

PROTECTIVE BONDING CIRCUIT

375B

324

18V

303

304A

H1 H3 H4 H5 H6

FAN

CR1

H1A

3524

H2H1 H3 H4 H5 H6

H2H4H6

H3A

H3C

H3D

H1D

H1C

H1B

H1D

FAN RELAY

207

209

H1B

N.C.

209

208

204

201

205

206 203A

207A

202A

SWITCH PC BOARD

CONTROL PC BOARD

CASE

BACK

GND2

GND1

LINE CORD

208

204

201

205

SHUNT

REACTOR

MAIN

TRANSFORMER

D1A

D1B

D2A

D2B

X8X5X1

OUTPUT RECTIFIER

207A

382

383

388

387

REMOTE

RECEPTACLE

SNUBBER PC BOARD

386

385

384

381

201

205

204

208

207A

202A

206

203A

209

R222

W221

CASE FRONT (REAR VIEW)

TP4

TP6

TP5

AUXILIARY

TRANSFORMER

D3A

D3B

HEAT SINK

229

376W327

324B375

303

R(T4)

R(T3)

W(T4)

310

307

308

313

J10

377

328

304

330

234

101112

309

311

387

388

316

320

382

383

229

380

277

245

R222

W221

318

317

(W)

(V)

(U)

W(T3)

380

LOCAL

REMOTE

304A

330

277

202

206

203A

202

202A

203

207

PRIMARY RECONNECT SWITCHE S

(REAR VIEW)

(SHOWN IN 380-575V POSITION)

S2A

S2B

311

310

308

313

307

309

204

205

C1,C2 SWITCH BOARD CAPACITORS, 2200/500

C3,C4 OUTPUT BY-PASS CAPACITORS, .05/600

CR1 FAN RELAY COIL, 12V DC

D1A,D1B OUTPUT DIODE,

D2A,D2B OUTPUT DIODE,

D3A,D3B OUTPUT DIODE,

D4 INPUT RECITIER BRIDGE

L1,L2 OUTPUT REACTOR

L3 OUT PUT INDUCTOR (CHOKE)

L4,L5 RF TOROID CHOKES

R1 OUTPUT CONTROL POTENTIOMETER,10K/2

R2 ARC FORCE POTENTIOMETER, 10K/2

R3,R4 OUTPUT LOAD RESISTORS, 100/25

S1 INPUT POWER SWITC H

S2A,S2B RECONNECT SW ITCHES

S3 OUTPUT RECTIFIER HEATSINK THERMOSTAT

S4 SWITCH BOARD HEATSINK THERMOSTAT

S5 CHOKE THERMOSTAT

T1 MAIN TRANSFORMER

T2 AUXILIARY TRANSFORMER

T3,T4 CURRENT TRANSFORMER

TP1,TP2,TP3 INPUT MOV, 660V AC

TP4,TP5 OUTPUT MOV, 320V AC

TP6 OUTPUT MOV, 150V AC

N.E.

NOTES:

N.A. MACHINES WITH RED, BLACK AND WHITE POWER CORDS:

FOR

SINGLE PHASE INPUT:

CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.

CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR TH

REE PHASE INPUT:

CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 575V OPERATION.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.

N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6.

OUTPUT

CHOKE

316

318

317

319

320

N.D.

N.A.

WIRING DIAGRAMS

WIRING DIAGRAM- CODE: 10994

F-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside 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..

ES 275i

F-2

ARC FORCE

WELD

MODE

OFF

328

327

304

SMAW

GTAW

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.

OHMS/WATTS

COMPONENT VALUE

UNITS:

RESISTORS:

MFD/VOLTS

CAPACITORS:

LATCH

0F CONNECTOR J5

EXAMPLE: THIS IS PIN 7

LEAD COLORING CODE:

B-BLACK

G-GREEN

O-ORANGE

R-RED

CONNECTOR PIN NUMBERS:

U-BLUE

Y-YELLOW

W-WHITE

G4365-4

WIRING DIAGRAM - RED-D-ARC ES275i

HOT

START

THERMAL

PRI

-O

-I

TP1

INPUT

BRIDGE

POWER SWITCH

OUTPUT

376

375

377

TP2

TP3

380-

415V

575V

220-

230V

440-

460V

208V

0.6 AMP SLOW BLOW

RI-

-OUT

BASE

CASE

FRONT

PROTECTIVE BONDING CIRCUIT

375B

324

18V

303

304A

H1 H3 H4 H5 H6

FAN

CR1

H1A

3524

H2H1 H3 H4 H5 H6

H2H4H6

H3A

H3C

H3D

H1D

H1C

H1B

H1D

FAN RELAY

207

209

H1B

N.C.

209

208

204

201

205

206 203A

207A

202A

SWITCH PC BOARD

CONTROL PC BOARD

CASE

BACK

GND2

GND1

LINE CORD

208

204

201

205

SHUNT

REACTOR

MAIN

TRANSFORMER

D1A

D1B

D2A

D2B

X8X5X1

OUTPUT RECTIFIER

207A

382

383

388

387

REMOTE

RECEPTACLE

SNUBBER PC BOARD

386

385

384

381

201

205

204

208

207A

202A

206

203A

209

R222

W221

CASE FRONT (REAR VIEW)

TP4

TP6

TP5

AUXILIARY

TRANSFORMER

D3A

D3B

HEAT SINK

229

376W327

324B375

303

R(T4)

R(T3)

W(T4)

310

307

308

313

J10

377

328

304

330

234

101112

309

311

387

388

316

320

382

383

229

380

277

245

R222

W221

318

317

(W)

(V)

(U)

W(T3)

380

LOCAL

REMOTE

304A

330

277

202

206

203A

202

202A

203

207

PRIMARY RECONNECT SWITCHE S

(REAR VIEW)

(SHOWN IN 380-575V POSITION)

S2A

S2B

311

310

308

313

307

309

204

205

C1,C2 SWITCH BOARD CAPACITORS, 2200/500

C3,C4 OUTPUT BY-PASS CAPACITORS, .05/600

CR1 FAN RELAY COIL, 12V DC

D1A,D1B OUTPUT DIODE,

D2A,D2B OUTPUT DIODE,

D3A,D3B OUTPUT DIODE,

D4 INPUT RECITIER BRIDGE

L1,L2 OUTPUT REACTOR

L3 OUTPUT INDUCTOR (CHOKE)

L4,L5 RF TOROID CHOKES

R1 OUTPUT CONTROL POTENTIOMETER,10K/2

R2 ARC FORCE POTENTIOMETER, 10K/2

R3,R4 OUTPUT LOAD RESISTORS, 100/25

S1 INPUT POWER SWIT CH

S2A,S2B RECONNECT SWITCHES

S3 OUTPUT RECTIFIER HEATSINK THERMOSTAT

S4 SWITCH BOARD HEATSINK THERMOSTAT

S5 CHOKE THERMOSTAT

T1 MAIN TRANSFORMER

T2 AUXILIARY TRANSFORMER

T3,T4 CURRENT TRANSFORMER

TP1,TP2,TP3 INPUT MOV, 660V AC

TP4,TP5 OUTPUT MOV, 320V AC

TP6 OUTPUT MOV, 150V AC

N.E.

NOTES:

N.A. MACHINES WITH RED, BLACK AND WHITE POWER CORDS:

FOR

SINGLE PHASE INPUT:

CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.

CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR TH

REE PHASE INPUT:

CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 575V OPERATION.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.

N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6.

OUTPUT

CHOKE

316

318

317

319

320

N.D.

N.A.

WIRING DIAGRAMS

WIRING DIAGRAM- CODE: 11166, 11223

F-2

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..

ES 275i

F-3

ARC FORCE

WELD

MODE

OFF

328

327

304

SMAW

GTAW

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.

OHMS/WATTS

COMPONENT VALUE

UNITS:

RESISTORS:

MFD/VOLTS

CAPACITORS:

LATCH

0F CONNECTOR J5

EXAMPLE: THIS IS PIN 7

LEAD COLORING CODE:

B-BLACK

G-GREEN

O-ORANGE

R-RED

CONNECTOR PIN NUMBERS:

U-BLUE

Y-YELLOW

W-WHITE

G4365-5

WIRING DIAGRAM - RED-D-ARC ES275i

HOT

START

THERMAL

PRI

-O

-I

TP1

INPUT

BRIDGE

POWER SWITCH

OUTPUT

376

375

377

TP2

TP3

380-

415V

575V

220-

230V

440-

460V

208V

0.6 AMP SLOW BLOW

RI-

-OUT

BASE

CASE

FRONT

PROTECTIVE BONDING CIRCUIT

375B

324

18V

303

304A

H1 H3 H4 H5 H6

FAN

CR1

H1A

3524

H2H1 H3 H4 H5 H6

H2H4H6

H3A

H3C

H3D

H1D

H1C

H1B

H1D

FAN RELAY

207

209

H1B

N.C.

209

208

204

201

205

206 203A

207A

202A

SWITCH PC BOARD

CONTROL PC BOARD

CASE

BACK

GND2

GND1

LINE CORD

208

204

201

205

SHUNT

REACTOR

MAIN

TRANSFORMER

207A

382

383

388

387

REMOTE

RECEPTACLE

386

385

384

201

205

204

208

207A

202A

206

203A

209

R222

W221

CASE FRONT (REAR VIEW)

TP4

TP6

TP5

AUXILIARY

TRANSFORMER

229

376W327

324B375

303

R(T4)

R(T3)

W(T4)

310

307

308

313

J10

377

328

304

330

234

101112

309

311

387

388

316

320

382

383

229

380

277

245

R222

W221

318

317

(W)

(V)

(U)

W(T3)

380

LOCAL

REMOTE

304A

330

277

202

206

203A

202

202A

203

207

PRIMARY RECONNECT SWITCHE S

(REAR VIEW)

(SHOWN IN 380-575V POSITION)

S2A

S2B

311

310

308

313

307

309

204

205

C1,C2 SWITCH BOARD CAPACITORS, 2200/500

C3,C4 OUTPUT BY-PASS CAPACITORS, .05/600

CR1 FAN RELAY COIL, 12V DC

D4 INPUT RECITIER BR IDGE

L1,L2 O UTPUT RE ACTOR

L3 O UTPUT INDUCTOR (CHOKE)

L4,L5 RF TOROID CHOKE S

R1 OUTPUT CONTROL POTE NTIOMETER,10K/ 2

R2 ARC FORCE POTENTIOMETER, 10K/2

R3,R4 OUTP UT LOAD RESISTORS, 100/25

S1 INP UT POWER SWITCH

S2A,S2B RECONNECT SWITCHES

S3 OUTPUT RECTIFIER HEATSINK THERMOSTAT

S4 SWITCH BOARD HEATSINK THERMOSTAT

S5 CHOKE THERMOSTAT

T1 MAI N TRANS FORM ER

T2 AUXILIARY TRANSFORMER

T3,T4 CURRE NT TRANSFORMER

TP1,TP2,TP3 INP UT M OV, 660V AC

TP4,TP5 OUTPUT MOV, 320V AC

TP6 OUTPUT MOV, 150V AC

N.E.

NOTES:

N.A. MACHINES WITH RED, BLACK AND WHITE POWER CORDS:

FOR

SINGLE PHASE INPUT:

CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.

CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.

FOR TH

REE PHASE INPUT:

CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 575V OPERATION.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING

THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.

N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.

N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6.

N.A.

OUTPUT RECTIFIER PC BOARD

OUTPUT

CHOKE

316

318

317

319

320

N.D.

HEAT SINK

WIRING DIAGRAMS

WIRING DIAGRAM- CODES: 11266

F-3

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted

inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

ES 275i

F-4

DIAGRAMS

15.89

16.84

F-4

A.02

L11981

1.44

20.25

DIMENSION PRINT

2.08

3.17 MAX

.79 MIN

OPEN

4.30 MAX

RECONNECT DOOR

11.85

.88

.35 TYP.

9.00

7.00

.93

1.25

.25

ES 275i

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

Red-D-Arc IM803-B, ES 275i Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual