FOR ENGINE · 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding...

RED-D-ARC ES 275iIM803-CFebruary, 2011

Red-D-Arc Spec-Built Welding EquipmentThis RED-D-ARC welder is built to RED-D-ARC Extreme Dutydesign specifications by Lincoln Electric.Safety Depends on YouThis 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.

For use with machines having Code Numbers: 10994, 11166, 11223, 11773

The Global Leader in Welder Rentals

OPERATOR’S MANUAL

(

RED-D-ARC ES 275i

IM803-CFebruary, 2011

Red-D-Arc Spec-Built Welding EquipmentThis RED-D-ARC welder is built to RED-D-ARC Extreme Dutydesign specifications by Lincoln Electric.

Safety Depends on YouThis 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.

For use with machines having Code Numbers: 10994, 11166, 11223, 11773

The Global Leader in Welder Rentals

OPERATOR’S MANUAL

(

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

bE SuRE ThAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDuRES AREPERFORMED ONLY bY QuALIFIED INDIVIDuALS.

WARNING

ELECTRIC AND MAGNETIC FIELDSmay 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.

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.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

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

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

ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.

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

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

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

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanicalventilation. In confined spaces or in some circum-stances, outdoors, a respirator may be required.Additional precautions are also required when weldingon galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

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

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

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

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

7.c. Cylinders should be located:•Away from areas where they may be struck or subjected tophysical damage.

•A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

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

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

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

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

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

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

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

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

ivSAFETYiv

PRÉCAuTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-

tions 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 soud-

er 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.

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

téger contre les chutes dans le cas ou on recoit un choc. Ne

jamais enrouler le câble-électrode autour de 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-inflamma-

bles.

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.

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 lev-

age, 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 forte-

ment 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.

PRÉCAuTIONS DE SÛRETÉ POuRLES MAChINES À SOuDER ÀTRANSFORMATEuR ET ÀREDRESSEuR

1. Relier à la terre le chassis du poste conformement au code

de l’électricité et aux recommendations du fabricant. Le dis-

positif 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.

vv

Thank You for selecting one of our QUALITY products. We want you to takepride in operating this product ••• as much pride as we have inbringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

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

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

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code (if available)______________________________________________________

Serial Number (if available)__________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above.

CUSTOMER ASSISTANCE POLICYThe business of our company is manufacturing and selling high quality welding equipment. Our challenge is tomeet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us foradvice or information about their use of our products. We respond to our customers based on the best informa-tion in our possession at that time. We are not in a position to warrant or guarantee such advice, and assume noliability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including anywarranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matterof practical consideration, we also cannot assume any responsibility for updating or correcting any such informa-tion or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

We are a responsive manufacturer, but the selection and use of specific products sold by us is solely within thecontrol of, and remains the sole responsibility of the customer. Many variables beyond our control affect theresults obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing.

vi vi TAbLE OF CONTENTSPage

Installation.......................................................................................................................Section ATechnical Specifications.......................................................................................................A-1Safety Precautions. ..............................................................................................................A-2Suitable Location..................................................................................................................A-2

Stacking ........................................................................................................................A-2Tilting.............................................................................................................................A-2High Frequency Protection............................................................................................A-2

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

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

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

Operation.........................................................................................................................Section bSafety Precautions ...............................................................................................................B-1General Description..............................................................................................................B-1

Operational Features ....................................................................................................B-1Welding Capability ........................................................................................................B-1Limitations .....................................................................................................................B-1

Controls and Settings ....................................................................................................B-2,B-3Constant Current Processes ................................................................................................B-3Parallel Operation.................................................................................................................B-3Overload Protection..............................................................................................................B-4Thermal Protection ...............................................................................................................B-4Fan ......................................................................................................................................B-4Power-Up Sequence ............................................................................................................B-4

________________________________________________________________________________

Maintenance........................................................................................................Section DInput Filter Capacitor Discharge Procedure ..........................................................D-1Routine Maintenance.............................................................................................D-2Filter Capacitor Conditioning .................................................................................D-2Location of Maintenance Components ..................................................................D-3

________________________________________________________________________________

Troubleshooting .................................................................................................Section ESafety Precautions.................................................................................................E-1PC Board Troubleshooting Procedures.................................................................E-2Troubleshooting Guide.............................................................................E-3 thru E-7

________________________________________________________________________________

Wiring Diagrams and Dimension Print .............................................................Section F________________________________________________________________________________

Parts Pages ....................................................................................................P-477 Series________________________________________________________________________________

ES 275i

A-1INSTALLATION A-1

height Width Depth Weight (With Cord)13.6in.(345mm) - Handle Folded Down 20.25 in.(514mm)

9.0 in.(229mm) 54.5lbs. (24.7Kg)16in.(406mm) - Handle Up 21.7 in.(551)-With Cord Strain Relief

PhYSICAL DIMENSIONS

ThREE PhASE SINGLE PhASERECOMMENDED MINIMuM INPuT WIRE AND FuSE SIzES

Input Voltage-hz

208/230-60460/575-60

220-50380/400/415-50

440-50

Fuse Size(Time Delay Fuse)

Amps

6035

603535

Cord Size AWG(mm2)based on a type S, SJ, SJO

or SJT Flexible cordin 30°C Ambient

8(8.4)

14(2.5)

8(8.4)

12(4)

14(2.5)

(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.

Technical Specifications - ES 275i

INPuT AT RATED OuTPuT - ThREE PhASE ONLYINPuT VOLTS-hz

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

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

INPuTCuRRENT

AMPS

27/25/13/11

34/33/17/14

38/37/19/16

25/15/15/14/13

32/20/19/18/17

IdlePower

150W Max

IdlePower

150W Max

Efficiency@ Rated Output

87%

Efficiency@ Rated Output

87%

OuTPuT CONDITIONS

[email protected]%250A@30V. 60%275A@31V. 35%

[email protected]%250A@30V. 35%

INPuT AT RATED OuTPuT - SINGLE PhASE ONLYINPuT VOLTS-hz

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

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

INPuTCuRRENT

AMPS

55/48/26/21

72/62/33/27

80/70/38/31

48/32/30/29/27

63/42/40/38/36

OuTPuT CONDITIONS

[email protected]%250A@30V. 60%275A@31V.* 35%

[email protected]%250A@30V. 35%

OuTPuT (ThREE AND SINGLE PhASE)

Input Voltage-hz

208-60230-60

460/575-60

220-50380/400/415-50

440-50

Cord Size AWG(mm2)based on a type S, SJ, SJO

or SJT Flexible cordin 30°C Ambient

4 (25)1

6(16)1

10 (6)

6(16)1

8(10)

10(6)

Fuse Size(Time Delay Fuse)

Amps

10010060

1006060

TEMPERATuRE RANGES

OPERATING TEMPERATuRE RANGE-20°C to +40°C

STORAGE TEMPERATuRE RANGE-40°C to +40°C

WELDING NO LOAD CuRRENT RANGE VOLTAGE5-275 Amps 70 VDC

A-2INSTALLATION A-2

Read this entire installation section before youstart installation.

SAFETY PRECAuTIONS

ELECTRIC ShOCK can kill.• have an electrician install and

service this equipment.

• Turn the input power off at thefuse box before working onequipment.

• Do not touch electrically hot parts.

• be sure to discharge capacitors with the proce-dure outlined in the Maintenance Section of thismanual before working in that area of theequipment.

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

SELECT SuITAbLE LOCATIONThe ES 275i will operate in harsh environments. Evenso, it is important that simple preventative measuresare followed in order to assure long life and reliableoperation.

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

• Dirt and dust that can be drawn into the machineshould be kept to a minimum. Failure to observethese precautions can result in excessive operatingtemperatures and nuisance shutdown.

• Keep machine dry. Shelter from rain and snow. Donot place on wet ground or in puddles.

• DO NOT MOuNT OVER COMbuSTIbLE SuRFACES.

Where there is a combustible surface directlyunder stationary or fixed electrical equipment,that surface shall be covered with a steel plate atleast .06”(1.6mm) thick, which shall extend notless than 5.90”(150mm) beyond the equipment onall sides.-----------------------------------------------------------------------

STACKING

ES 275i’s cannot be stacked.

TILTINGPlace the machine directly on a secure, level surface.The machine may topple over if this procedure is notfollowed.

hIGh FREQuENCY PROTECTIONLocate the ES 275i away from radio controlledmachinery.

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

INPuT CONNECTIONS

The ES 275i should be connected only by a qualifiedelectrician. Installation should be made in accordancewith all local and national electric codes and the infor-mation detailed below.

INPuT FuSE AND SuPPLY WIRERefer to the Technical Specifications page at thebeginning of this chapter for the proper fuse sizes andsupply cable sizes.

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

• Install the proper fuse in the fuse holder in the maindisconnect panel.

INPuT SuPPLY CONNECTIONSBe sure the voltage phase and frequency of the inputpower is as specified on the rating plate, located onthe 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 themachine. Follow the power cord connection instruc-tions. Incorrect connection may result in equipmentdamage.

Single Phase Input: Connect green lead to groundper National Electrical Code. Connect black and whiteor brown leads to power. Wrap red lead with tape toprovide 600V insulation.

Three Phase Input: Connect green lead to groundper National Electrical Code. Connect black, red andwhite or brown leads to power.

ES 275i

WARNING

CAuTION

CAuTION

ES 275i

OuTPuT CONNECTIONS

Refer to figure B.1 for the location of the 3-PinRemote 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 andWork Cable ( Copper Cable Rated at 75°C).

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

A-3INSTALLATION A-3

INPuT VOLTAGE RECONNECTPROCEDuRE

When received directly from the factory, units are con-nected for, 460 VAC. If 460 VAC is the desired input,then the machine may be connected to the power sys-tem without any setup required inside the reconnectdoor. For other voltages refer to the instructions locat-ed on the Reconnect Panel Access Door or follow theinstructions below.

Failure to follow these instructions can causeimmediate failure of components within thewelder.------------------------------------------------------------------------

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

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

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

....Do not touch electrically live parts.Only qualified persons should install,use or service this equipment.

RECONNECT PROCEDURE1. BE SURE POWER SWITCH IS OFF.

208V220-230V380-415V440-460V 575V 'A'

INPUT VOLTAGE RANGE. removed.Do not operate with wraparoundinspecting 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.

.

.

.

.

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.

Figure A.1 Input Voltage Reconnect Instructions

CAuTION

ES 275i

b-1OPERATIONb-1

GENERAL DESCRIPTION

The ES 275i is a 275 amp arc welding power sourcethat utilizes single or three phase input power, to pro-duce constant current output. The welding responseof 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 200amps, 100% duty cycle, and 250 amps, 60% dutycycle.

LIMITATIONS

The ES 275i is not recommended for pipe thawing.

Read and understand this entire section beforeoperating your machine.

SAFETY PRECAuTIONS

ELECTRIC ShOCK can kill.

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

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

____________________________________

____________________________________

____________________________________

____________________________________Only qualified personnel should operate this equip-ment. Observe all safety information throughout thismanual.

WARNING

FuMES AND GASEScan be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

ARC RAYScan burn.

• Wear eye, ear and bodyprotection.

WELDING, CuTTING and GOuGING SPARKScan cause fire or explosion

• Keep flammable material away.

• Do not weld, cut or gouge on contain-ers that have held combustibles.

b-2OPERATIONb-2

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

position to energize the machine. When the power is onthe output will be energized in STICK (SMAW) mode andTIG (GTAW) if the remote is set to local control. At powerup the thermal Light and Fan will turn on for approxi-mately 3 seconds.

2. OuTPuT CONTROL - This controls the output

current. Control is provided over the entire output rangeof the power source with (1) turn of the control knob. Thiscontrol may be adjusted while under load to changepower source output. When using remote control thisfunction becomes the limit setting.

3. LOCAL/REMOTE SWITCh - Place in the

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

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

TIG (GTAW) Optimized for touch start use. Short circuitcurrent is limited to approximately 20 amps to aid in touchstarting.

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

gy in CC Stick (SMAW). The Hot Start can be eitherturned on or off. When on, it provides a striking current at260% of the set current or 275A whichever is larger thenquickly 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 issoft at the minimum settings and more forceful ordriving at the maximum settings. Higher spatterlevels may be present at the maximum settings.Full range is from -10(Soft) to +10(Crisp)

ES 275i

CONTROLS AND SETTINGS

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

FIGuRE b.1 — CASE FRONT CONTROLS.

LOCALREMOTE

REMOTE

ARC FORCE HOT START-10 +10

OUTPUTCC STICKTIG ON

ON

OFF

OFFOFF

LOCAL

REMOTE

REMOTE

ARC FORCEHOT START

-10 +10

OUTPUT

CC STICK

TIG

ON

ON

OFF

OFFOFF

1

2

3

4

9

7

6

8

5

10

b-3OPERATIONb-3

7. OuTPuT TERMINALS - These quick discon-

nect terminals are compatible with TWECO®* con-nectors. The terminal provide connection points forthe electrode and work cables. Refer to OutputConnection in the Installation chapter for propercable sizes. For positive polarity welding connectthe electrode cable to the positive terminal and thework cable to the negative terminal. To weld nega-tive 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 thermostathas been activated. Machine output will return afterthe internal components have returned to a normaloperating temperature. See Thermal Protectionlater in this Operation chapter.

9. 3-PIN REMOTE RECEPTACLE 3-Pin remote control allows for remote control ofthe 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 elec-

trode holder being the only equipment required.

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 com-

pressed air are required.

TIG WELDING*The ES 275i is capable of touch start TIG welding. An

electrode cable, work cable, TIG torch, and gas sup-

ply 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 work-

piece.

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 cor-

rect this condition.

PARALLEL OPERATIONThe Invertec’s are operable in parallel. For bestresults, the currents of each machine should be rea-sonably well shared. As an example, with twomachines set up in parallel for a 300 amp procedure,each machine should be set to deliver approximately150 amps, not 200 amps from one and 100 ampsfrom the other. This will minimize nuisance feedbackconditions. In general, more than two machines in par-allel will not be effective due to the voltage require-ments of procedures in that power range.

To set machine outputs, start with output control potsand arc force pots in identical positions. Adjust out-puts and arc forces to maintain current sharing whileestablishing the proper output current.

ES 275i

b-4OPERATIONb-4

OVERLOAD PROTECTIONThe machine is electrically protected from producinghigh output currents. Should the output currentexceed 300A, an electronic protection circuit willreduce the current to less than 200A. The machinewill continue to produce this low current until the pro-tection circuit is reset. Reset occurs when the outputload is removed.

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

ThERMAL PROTECTIONThermostats protect the machine from excessiveoperating temperatures. Excessive temperatures maybe caused by a lack of cooling air or operating themachine beyond the duty cycle and output rating. Ifexcessive operating temperature should occur, thethermostats will prevent output voltage or current.

Thermostats are self-resetting once the machine coolssufficiently.

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

The fan will also run anytime the machine has overheated.

POWER-uP SEQuENCEAt power up the thermal light (and Power light oncodes 11164 and above) turns on and the fans run forapproximately 3 seconds. This is the pre-charge timefor the main capacitors. After this time the fans andthermal light turn off and the pre-charge relay closesto apply full line power to the capacitors. At this timethe machine is ready to weld.

ES 275i

D-1MAINTENANCED-1

INPuT FILTER CAPACITORDISChARGE 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 resis-

tor 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 pli-

ers. Hold body of the resistor and connect resistor

leads across the two capacitor terminals. Hold

resistor in place for 10 seconds. DO NOT TOUCH

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.

ES 275i

ELECTRIC ShOCK can kill.

• Have an electrician install and servicethis equipment.

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

• Do not touch electrically hot parts.• Prior to Performing preventative main-

tenance, perform the following capaci-tor discharge procedure to avoid elec-tric shock.

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

WARNING

UPPER CAPACITOR TERMINALS

LOWER CAPACITOR TERMINALS

INSULATEDGLOVES

INSULATEDPLIERS

POWERRESISTOR

POWERBOARD

RIGHT SIDE OF MACHINE

UPPER

CAPACITOR TERMINALS

LOWER

CAPACITOR

TERMINALS

INSULATED

GLOVES

INSULATED

PLIERS

POWER

RESISTOR

POWER

BOARD

RIGHT SIDE OF MACHINE

FIGuRE D.1 — LOCATION OF INPuT FILTER CAPACITOR TERMINALS.

D-2MAINTENANCED-2

ROuTINE MAINTENANCE

1. Perform the following preventive maintenance pro-cedures at least once every six months. It is goodpractice to keep a preventive maintenance record;a record tag attached to the machine works best.

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

3. Keeping the machine clean will result in cooleroperation and higher reliability. Be sure to clean thefollowing areas with a low pressure air stream. Seefigure D.2 for component locations.

•Power and control printed circuit boards

•Power switch

•Main transformer

•Input rectifier

•Heat sink fins

•Input Filter Capacitors

•Output Terminals

4. Examine capacitors for leakage or oozing. Replace

if needed.

5. Examine the sheet metal case for dents or break-age. Repair the case as required. Keep the case ingood condition to ensure that high voltage parts areprotected and correct spacings are maintained. Allexternal sheet metal screws must be in place toassure case strength and electrical ground continu-ity.

6. Check electrical ground continuity. Using an ohm-

meter, measure resistance between either output

terminal and an unpainted surface of the machine

case. (See Figure D.2 for locations.) Meter reading

should be 500,000 ohms or more. If meter reading

is less than 500,000 ohms, check for electrical com-

ponents that are not properly insulated from the

case. Correct insulation if needed.

7. Replace machine cover and screws.

ES 275i

ES 275i

D-3MAINTENANCED-3

FIGuRE D.2 — LOCATION OF MAINTENANCE COMPONENTS.

SWITCH BOARD &HEAT SINK ASSEMBLY

CONTROL PC BOARDMAIN TRANSFORMER ASSEMBLY

CHOKE ASSEMBLYOUTPUT TERMINALS POWER SWITCH

CENTER ASSEMBLY

COOLING FANS

CASE BACK ASSEMBLYCASE FRONT ASSEMBLY

WRAP-AROUND

BASE

INPUT RECTIFIER

OUTPUTRECTIFIERASSEMBLY

SWITCH BOARD &

HEAT SINK ASSEMBLY

CONTROL PC BOARD

MAIN TRANSFORMER ASSEMBLY

CHOKE ASSEMBLY

OUTPUT TERMINALS

POWER SWITCH

CENTER ASSEMBLY

COOLING FANS

CASE BACK ASSEMBLY

CASE FRONT ASSEMBLY

WRAP-AROUND

BASE

INPUT RECTIFIER

OUTPUT

RECTIFIER

ASSEMBLY

ES 275i

E-1TROubLEShOOTING E-1

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

CAuTION

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

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for thePossible Cause, generally it states to contact yourlocal Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Authorized Field Service Facility.

hOW TO uSE TROubLEShOOTING GuIDE

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

__________________________________________________________________________

WARNING

ES 275i

E-2TROubLEShOOTING & REPAIRE-2

_______________________________CAuTION: Sometimes machine failuresappear to be due to PC board failures. Theseproblems can sometimes be traced to poorelectrical connections. To avoid problemswhen troubleshooting and replacing PCboards, please use the following procedure:

1. Determine to the best of your technicalability that the PC board is the most likelycomponent causing the failure symptom.

2. Check for loose connections at the PCboard to assure that the PC board is prop-erly connected.

3. If the problem persists, replace the sus-pect PC board using standard practices toavoid static electrical damage and electri-cal shock. Read the warning inside thestatic resistant bag and perform the follow-ing procedures:

P.C. board can be dam-aged by static electricity.

- Remove your body’s stat-ic charge before openingthe static-shielding bag.Wear an anti-static wriststrap. For safety, use a 1Meg ohm resistive cordconnected to a groundedpart of the equipmentframe.

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

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

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

ELECTRIC ShOCK can kill.have an electrician installand service this equip-ment. Turn the input powerOFF at the fuse box beforeworking on equipment. Donot touch electrically hotparts.

- Remove the P.C. Board from the static-shielding bag and place it directly into theequipment. Don’t set the P.C. Board on ornear paper, plastic or cloth which could havea static charge. If the P.C. Board can’t beinstalled immediately, put it back in the static-shielding bag.

- If the P.C. Board uses protective shortingjumpers, don’t remove them until installationis complete.

- If you return a P.C. Board for credit, it mustbe in the static-shielding bag. This will preventfurther damage and allow proper failure analy-sis.

4. Test the machine to determine if the fail-ure symptom has been corrected by thereplacement PC board.

NOTE: It is desirable to have a spare (knowngood) PC board available for PC board trou-bleshooting.

NOTE: Allow the machine to heat up so thatall electrical components can reach their oper-ating temperature.

5. Remove the replacement PC board andsubstitute it with the original PC board torecreate the original problem.

a. If the original problem does not reap-pear by substituting the originalboard, then the PC board was not theproblem. Continue to look for badconnections in the control wiring har-ness, junction blocks, and terminalstrips.

b. If the original problem is recreated bythe substitution of the original board,then the PC board was the problem.Reinstall the replacement PC boardand test the machine.

6. Always indicate that this procedure wasfollowed when warranty reports are to besubmitted.

NOTE: Following this procedure and writing on thewarranty report, “INSTALLED AND SWITCHED PCBOARDS TO VERIFY PROBLEM,” will help avoiddenial of legitimate PC board warranty claims.

PC bOARD TROubLEShOOTING PROCEDuRES

WARNING

ATTENTIONStatic-SensitiveDeviceshandle only atStatic-SafeWorkstations

Reusable ContainerDo Not Destroy

ES 275i


Observe all Safety Guidelines detailed throughout this manual

OuTPuT PRObLEMS

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE

RECOMMENDEDCOuRSE OF ACTION

Major physical or electrical damageis observed when cover wrap-aroundis removed.

The machine is dead - no output.

No output but the fan operates nor-mally.

1. The input power switch must bein the ON position.

2. Make sure the input voltage iscorrect for the machine.

3. If the machine is set for single-phase operation, inspect toassure that the WHITE andBLACK leads are connectedproperly and the RED lead is notconnected and is insulated.

4. Check that the input voltage set-up switch and jumper “A” (thereconnect auxiliary jumper) are inthe proper position for the inputvoltage being applied. Refer toInput Voltage ReconnectProcedure in the InstallationChapter.

5. Check continuity of the 0.6-ampslow blow fuse located on thereconnect panel.

1. If the machine has not been usedfor a long time and is connectedfor 380 VAC or higher, thecapacitors may need “condition-ing”. See Input Filter CapacitorConditioning.

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

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Authorized Field ServiceFacility.

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

CAuTION

ES 275i



OuTPuT PRObLEMS

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


Output turns on momentarily, thenswitches off and repeats cycle.

Remote output control not functioning. The machine operatesnormally on LOCAL control.

1. Check the input voltages andreconnection procedures. Makesure the input voltage is correctfor the machine. See Input

Voltage Reconnect Procedure.

2. Check or replace remote controldevice. (If used)

1. Make sure the Local/Remoteswitch (S3) is in the REMOTEposition.

2. The remote control device maybe faulty. Replace.

3. The Local/Remote switch mustbe in the LOCAL position unlessa remote control device isattached to the remotereceptacle.



CAuTION

ES 275i



OuTPuT PRObLEMS

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


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

The machine operates normallywhen connected for 200 - 230VACinput. There is no output when themachine is connected to 380VAC orhigher.

1. Inspect input leads for possibleshorts or grounds or mis-connec-tions.

2. Install new fuses and reapplypower. If fuses open again, con-sult a Authorized Field ServiceFacility.

1. Check the input voltage and inputvoltage reconnect procedures.See Installation Section of thismanual.



CAuTION

ES 275i



OuTPuT PRObLEMS

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


The machine will not produce morethan 200 amps.

1. This may be normal operation. Ifthe output current exceeds 300amps, an electronic protectioncircuit will reduce the current toless than 200 amps. The machinewill continue to produce this lowcurrent until the protection circuitis reset. Reset occurs when theoutput load is removed.

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

3. Check for loose or faulty weldingcables.



CAuTION

ES 275i



WELDING PRObLEMS

PRObLEMS(SYMPTOMS)

POSSIbLE CAuSE


Poor welding, weld settings drift, oroutput power is low.

Poor stick electrode welding performance. The arc pops out.

The thermal light and fan keep turn-ing on and off.

1. Make sure the machine settingsare correct for the weld processbeing used.

2. Check machine performance onLOCAL control. If OK then theremote control device may befaulty. Check or replace.

3. Check the input voltages andinput voltage reconnectprocedures. See InstallationSection of this manual.



2. Is the electrode DRY? Try weld-ing with another electrode from adifferent container. Make sureyou have the correct electrode forthe application.

3. Make sure the machine settingsare correct for the weld processbeing used.

1. Check the input voltage section.

2. Check for blockage of vents,which restricts air flow into or outof the machine.



CAuTION

F-1WIRING DIAGRAMSF-1

ES 275i

R2ARC FORCE

WELD MODE

OFF

328 327

304SMAW GTAW

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.OHMS/WATTSCOMPONENT VALUE UNITS: RESISTORS: MFD/VOLTSCAPACITORS: 8

LATCH0F CONNECTOR J5EXAMPLE: THIS IS PIN 7 32

LEAD COLORING CODE: B-BLACK 21 8G-GREEN O-ORANGE R-RED CONNECTOR PIN NUMBERS: 7 14U-BLUE Y-YELLOWW-WHITE 13 J5R4 G4365-2A

WIRING DIAGR

AM - RED-D-A

RC ES275i ON HOT STARTYTHERMAL +- WB

3 267PRI-OUT PRI-IN SEC BOOSTTP1INPUT BRIDGE _ + DE BC F A_

POWER SWITCHW B

R1OUTPUT 376 375 377

TP2 TP3 380- 415V 575V220- 230V 440- 460V208V0.6 AMP SLOW BLOW

SEC BOOSTPRI-INPRI-OUT

BASECASE FRONT PROTECTIVE BONDING CIRCUIT375B 375B 324

H2 18V UW1

303304A

H1H3H4H5H6

FAN FAN

CR1 CR148 0 1 26H1A

63524H2H1H3H4H5H6

H1H2 H4 H6

H3 H5H3A

H3A H3C H3D H1DH1C

H1CH1B H1DFAN RELAY

R

207 209A1 H1B A1A A N.C.

209208204 201 205 206203A207A202A

77 7675

SWITCH PC BOARDCONTROL PC BOARD

CASE BACKGND2GGND1 LINE CORD

208 204 201205

SHUNT X4 X2X4 L1

X2

X7

X8

X5

X6X1 X3

REACTOR L2 REACTOR

MAIN TRANSFORMER

D1AD1B D2AD2BX7 X6

RIGHT

LEFT

X8

X5

X1 X3OUTPUT RECTIFIER

207A

382383

388 387

REMOTE RECEPTACLE

SNUBBER PC BOARD

R3 386385384

381

201 205204 208 W RC2 C1207A 202A 206 203A

209

R222W221L4 L5CASE FRONT (REAR VIEW) TP4 C4C3TP6 TP5

W R T1T4T3

AUXILIARY TRANSFORMER T2

D3AD3BHEAT SINK

229

376 W 327 324 B 375 303

R(T4) R(T3)W(T4) 310 307 308313J10

J3 J4

377 328 304 3301 2 3 4 65

1 2 3 46 57 8 9 10 11 12

309 31198 7 10

387 388 316 320 382 383 229 380J2 277 76 751 2 4 5 87 6 12 3 9

R222 W2211 2

10 11J1

318 317 S4

L1 L2 L3

L1 L2 L3(W) (V) (U)

W(T3)

S1

D4 J5

BA C

380

LOCAL REMOTE304A33077 277

202206 203A 202202A 203 203207 PRIMARY RECONNECT SWITCHES (REAR VIEW) (SHOWN IN 380-575V POSITION)S2AS2B

311 310 308313 307 3091 4 27 8 653

204 205

C1,C2SWITCH BOARD CAPACITORS, 2200/50

0

C3,C4OUTPUT BY-PASS CAPACITORS, .05/60

0

CR1FAN RELAY COIL, 12V DC

D1A,D1BOUTPUT DIODE,



D4INPUT RECITIER BRIDGE

L1,L2OUTPUT REACTOR

L3OUTPUT INDUCTOR (CHOKE)

L4,L5RF TOROID CHOKES

R1OUTPUT CONTROL POTENTIOMETER,

10K/2

R2ARC FORCE POTENTIOMETER, 10K/2

R3,R4OUTPUT LOAD RESISTORS, 100/25

S1INPUT POWER SWITCH

S2A,S2BRECONNECT SWITCHES

S3OUTPUT RECTIFIER HEATSINK THERM

OSTAT

S4SWITCH BOARD HEATSINK THERMOS

TAT

S5CHOKE THERMOSTAT

T1MAIN TRANSFORMER

T2AUXILIARY TRANSFORMER

T3,T4CURRENT TRANSFORMER

TP1,TP2,TP3INPUT MOV, 660V AC

TP4,TP5OUTPUT MOV, 320V AC

TP6OUTPUT MOV, 150V ACN.E. NOTES: N.A. MACHINES WITH RE

D, BLACK AND WHITE POWER CORDS:

FOR SINGLE PHASE INPUT:CONNECT GREEN LEA

D TO GROUND PER NATIONAL ELECTRICAL CODE.

CONNECT BLACK AND WHITE LEADS TO SUPP

LY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600

V. INSULATION.

FOR THREE PHASE INPUT:CONNECT GREEN LEAD

TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SU

PPLY CIRCUIT.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECT

ION FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 575V OPERATIO

N.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PR

INTED CIRCUIT BOARD MAY CHANGE WITHOUT AF

FECTING

THE INTERCHANGEABILITY OF A COMPLETE B

OARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COM

MON CODE NUMBER.

N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PR

ESENT ON EARLIER MODELS.

N.E. LEADS #308 AND #309 MAY BE INTERCHANGED

IN J10 CONNECTOR PINS 2 AND 6.L3 OUTPUT CHOKE

316 S3 318317

S5319320 N.D.N.D.N.A. G

R2

AR

C F

OR

CE

WE

LD

MO

DE

OF

F

328

327

304

SM

AW

GT

AW

VIE

W O

F C

ON

NE

CT

OR

ON

PC

BO

AR

D

ELE

CT

RIC

AL S

YM

BO

LS

PE

R E

1537.

OH

MS

/WA

TT

S

CO

MP

ON

EN

T V

ALU

EU

NIT

S:

RE

SIS

TO

RS

:

MF

D/V

OLT

SC

AP

AC

ITO

RS

:

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H1C

H1C

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X8

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T2

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D3B

HE

AT

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229

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24

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73

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30

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1 2 3 4 65

1 2 3 46 57 8 9 10

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98 7 10

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.

N.D

.

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.

G

WIRING DIAGRAM- CODE: 10994

NOTE: This diagram is for reference only. It may not be accurate for all m

achines covered by this manual. The specific diagram for a particular code is pasted

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

F-2WIRING DIAGRAMSF-2

ES 275i

WIRING DIAGRAM- CODE: 11166, 11223

R2ARC FORCE

WELD MODE

OFF

328 327

304SMAW GTAW

VIEW OF CONNECTOR ON PC BOARD

ELECTRICAL SYMBOLS PER E1537.OHMS/WATTSCOMPONENT VALUE UNITS: RESISTORS: MFD/VOLTSCAPACITORS: 8

LATCH0F CONNECTOR J5EXAMPLE: THIS IS PIN 7 32

LEAD COLORING CODE: B-BLACK 21 8G-GREEN O-ORANGE R-RED CONNECTOR PIN NUMBERS: 7 14U-BLUE Y-YELLOWW-WHITE 13 J5R4 G4365-4A

WIRING DIAGR

AM - RED-D-A

RC ES275i ON HOT STARTYTHERMAL +- WB

3 267PRI-OUT PRI-IN SEC BOOSTTP1INPUT BRIDGE _ + DE BC F A_

POWER SWITCHW B

R1OUTPUT 376 375 377

TP2 TP3 380- 415V 575V220- 230V 440- 460V208V0.6 AMP SLOW BLOW

SEC BOOSTPRI-INPRI-OUT

BASECASE FRONT PROTECTIVE BONDING CIRCUIT375B 375B 324

H2 18V UW1

303304A

H1H3H4H5H6

FAN FAN

CR1 CR148 0 1 26H1A

63524H2H1H3H4H5H6

H1H2 H4 H6

H3 H5H3A

H3A H3C H3D H1DH1C

H1CH1B H1DFAN RELAY

R

207 209A1 H1B A1A A N.C.

209208204 201 205 206203A207A202A

77 7675

SWITCH PC BOARDCONTROL PC BOARD

CASE BACKGND2GGND1 LINE CORD

208 204 201205

SHUNT X4 X2X4 L1

X2

X7

X8

X5

X6X1 X3

REACTOR L2 REACTOR

MAIN TRANSFORMER

D1AD1B D2AD2BX7 X6

RIGHT

LEFT

X8

X5

X1 X3OUTPUT RECTIFIER

207A

382383

388 387

REMOTE RECEPTACLE

SNUBBER PC BOARD

R3 386385384

381

201 205204 208 W RC2 C1207A 202A 206 203A

209

R222W221L4 L5CASE FRONT (REAR VIEW) TP4 C4C3TP6 TP5

W R T1T4T3

AUXILIARY TRANSFORMER T2

D3AD3BHEAT SINK

229

376 W 327 324 B 375 303

R(T4) R(T3)W(T4) 310 307 308313

J10

J3 J4

377 328 304 3301 2 3 4 65

1 2 3 46 57 8 9 10 11 12

309 31198 7 10

387 388 316 320 382 383 229 380J2 277 76 751 2 4 5 87 6 12 3 9

R222 W2211 2

10 11J1

318 317 S4

L1 L2 L3

L1 L2 L3(W) (V) (U)

W(T3)

S1

D4 J5

BA C

380

LOCAL REMOTE304A33077 277

202206 203A 202202A 203 203207 PRIMARY RECONNECT SWITCHES (REAR VIEW) (SHOWN IN 380-575V POSITION)S2AS2B

311 310 308313 307 3091 4 27 8 653

204 205

C1,C2SWITCH BOARD CAPACITORS, 2200/500

C3,C4OUTPUT BY-PASS CAPACITORS, .05/60

0

CR1FAN RELAY COIL, 12V DC




D4INPUT RECITIER BRIDGE

L1,L2OUTPUT REACTOR

L3OUTPUT INDUCTOR (CHOKE)

L4,L5RF TOROID CHOKES

R1OUTPUT CONTROL POTENTIOMETER,1

0K/2

R2ARC FORCE POTENTIOMETER, 10K/2

R3,R4OUTPUT LOAD RESISTORS, 100/25

S1INPUT POWER SWITCH

S2A,S2BRECONNECT SWITCHES

S3OUTPUT RECTIFIER HEATSINK THERMO

STAT

S4SWITCH BOARD HEATSINK THERMOSTA

T

S5CHOKE THERMOSTAT

T1MAIN TRANSFORMER

T2AUXILIARY TRANSFORMER

T3,T4CURRENT TRANSFORMER

TP1,TP2,TP3INPUT MOV, 660V AC

TP4,TP5OUTPUT MOV, 320V AC

TP6OUTPUT MOV, 150V ACN.E. NOTES: N.A. MACHINES WITH RED, BLACK AND WHITE POW

ER CORDS:

FOR SINGLE PHASE INPUT:CONNECT GREEN LEA

D TO GROUND PER NATIONAL ELECTRICAL CODE.

CONNECT BLACK AND WHITE LEADS TO SUPP

LY CIRCUIT.

WRAP RED LEAD WITH TAPE TO PROVIDE 600V

. INSULATION.

FOR THREE PHASE INPUT:CONNECT GREEN LEAD

TO GROUND PER NATIONAL ELECTRIC CODE.

CONNECT BLACK, RED & WHITE LEADS TO SUP

PLY CIRCUIT.

N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTI

ON FOR INPUT VOLTAGE.

CONNECTION SHOWN IS FOR 575V OPERATIO

N.

N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRIN

TED CIRCUIT BOARD MAY CHANGE WITHOUT AFFEC

TING

THE INTERCHANGEABILITY OF A COMPLETE B

OARD, THIS DIAGRAM MAY NOT SHOW THE EXACT

COMPONENTS OR CIRCUITRY HAVING A COM

MON CODE NUMBER.

N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PR

ESENT ON EARLIER MODELS.

N.E. LEADS #308 AND #309 MAY BE INTERCHANGED

IN J10 CONNECTOR PINS 2 AND 6.L3 OUTPUT CHOKE

316 S3 318317

S5319320 N.D.N.D.N.A. G

B

C3

G+- WB

R2

AR

C F

OR

CE

WE

LD

MO

DE

OF

F

328

327

304

SM

AW

GT

AW

VIE

W O

F C

ON

NE

CT

OR

ON

PC

BO

AR

D

EL

EC

TR

ICA

L S

YM

BO

LS

PE

R E

15

37

.

OH

MS

/WA

TT

S

CO

MP

ON

EN

T V

AL

UE

UN

ITS

:R

ES

IST

OR

S:

MF

D/V

OLT

SC

AP

AC

ITO

RS

:

8

LA

TC

H

0F

CO

NN

EC

TO

R J

5E

XA

MP

LE

: T

HIS

IS

PIN

7

32

LE

AD

CO

LO

RIN

G C

OD

E:

B-B

LA

CK 2

1 8

G-G

RE

EN

O-O

RA

NG

ER

-RE

D

CO

NN

EC

TO

R P

IN N

UM

BE

RS

:

7 14

U-B

LU

E

Y-Y

EL

LO

WW

-WH

ITE

1

3 J5

R4

G4365-4

A

WIR

ING

DIA

GR

AM

- R

ED

-D-A

RC

ES

275i

ON

HO

TS

TA

RT

Y

TH

ER

MA

L

+-

WB

3

26

7

PRI-OUT

PRI-IN

SEC BOOST

TP

1

INP

UT

BR

IDG

E _ + DEBC

F

A

_

PO

WE

R S

WIT

CH

W B

R1

OU

TP

UT

376

375

377

TP

2T

P3

38

0-

41

5V

575

V

22

0-

23

0V

44

0-

46

0V

20

8V

0.6

AM

PS

LO

W B

LO

W

SEC

BOOST

PRI-IN

PRI-OUT

BA

SE

CA

SE

FR

ON

T

PR

OT

EC

TIV

E B

ON

DIN

G C

IRC

UIT

375B

37

5B

32

4

H2

18VU

W

1

30

3

30

4A

H1

H3

H4

H5

H6

FA

N

FA

N

CR

1C

R1

48

01

26

H1

A

63

52

4

H2

H1

H3

H4

H5

H6

H1

H2

H4

H6

H3

H5

H3

A

H3A

H3

C

H3

D

H1

D

H1

C

H1

C

H1

B

H1

D

FA

N R

EL

AY

R

20

7

20

9

A1

H1

B

A1

A

A

N.C

.

20

9

20

8

204

20

1

20

52

06

203

A

20

7A

202

A

77

76

75

SW

ITC

H P

C B

OA

RD

CO

NT

RO

L P

C B

OA

RD

CA

SE

BA

CK

GN

D2

G

GND1

LIN

E C

OR

D

20

8

20

4

20

120

5

SHUNT

X4

X2

X4

L1

X2

X7

X8

X5

X6

X1

X3

RE

AC

TO

R

L2

RE

AC

TO

R

MA

INT

RA

NS

FO

RM

ER

D1

AD

1B

D2

AD

2B

X7

X6

RIG

HT

LEFT

X8

X5

X1

X3

OU

TP

UT

RE

CT

IFIE

R

20

7A

382

38

3

388

387

RE

MO

TE

RE

CE

PT

AC

LE

SNUBBER PC BOARD

R3

38

6

385

38

4

381

20

1

20

5

20

4

20

8

WR

C2

C1

207A

202A

206

203A

209

R2

22

W2

21

L4

L5

CA

SE

FR

ON

T (

RE

AR

VIE

W)

TP

4

C4

C3

TP

6

TP

5

W R

T1

T4

T3

AUXILIARYTRANSFORMER

T2

D3

AD

3B

HE

AT

SIN

K

229

37

6W 32

73

24

B3

75

30

3

R(T

4)

R(T

3)

W(T

4)

31

03

07

30

83

13

J1

0

J3

J4

37

73

28

30

43

30

1 2 3 4 65

1 2 3 46 57 8 9 10

11

12

30

93

11

98 7 10

38

73

88

31

63

20

38

23

83

22

93

80

J2

27

77

67

5

1 2 4 5 87 6 12 3 9

R2

22

W2

21

1 2

10

11

J1

318

317 S4

L1

L2

L3

L1

L2

L3

(W)

(V)

(U)

W(T

3)

S1

D4

J5

B

AC

38

0

LO

CA

L

RE

MO

TE

30

4A

330

77

277

202

206

203A

202

202A

203

203

207

PR

IMA

RY

RE

CO

NN

EC

T S

WIT

CH

ES

(RE

AR

VIE

W)

(SH

OW

N I

N 3

80

-57

5V

PO

SIT

ION

)

S2A

S2B

31

1

31

0

30

8

31

33

07

30

9

1 4 27 8 653

20

4

20

5

C1

,C2

SW

ITC

H B

OA

RD

CA

PA

CIT

OR

S,

22

00/5

00

C3

,C4

OU

TP

UT

BY

-PA

SS

CA

PA

CIT

OR

S, .0

5/6

00

CR

1F

AN

RE

LA

Y C

OIL

, 1

2V

DC

D1

A,D

1B

OU

TP

UT

DIO

DE

,

D2

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F-3ELECTRICAL DIAGRAMSF-3

ES 275i

WIRING DIAGRAM- CODE: 11773




F-4DIAGRAMSF-4

ES 275i

L11981A.02

9.00

11.85

20.25

3.17MAX .79MIN .88

.25

7.00

16.842.08

4.30MAX RECONNECT DOOR OPEN 1.25O.93O

15.89

.35TYP.1.44

L11981

A.0

2

9.0

0

11

.85

20

.25

3.1

7M

AX

.79

MIN

.88

.25

7.0

0

16

.84

2.0

8

4.3

0M

AX

RE

CO

NN

EC

T D

OO

R

OP

EN

1.2

5O

.93

O

15

.89

.35

TY

P.

1.4

4

DIM

EN

SIO

N P

RIN

T

NOTES

ES 275i

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

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

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

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERSSIND EBENFALLS ZU BEACHTEN.

• Do not touch electrically live parts orelectrode with skin or wet clothing.

• Insulate yourself from work andground.

• No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

• Aislese del trabajo y de la tierra.

• Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

• Isolez-vous du travail et de la terre.

• Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

• Isolieren Sie sich von denElektroden und dem Erdboden!

• Não toque partes elétricas e electro-dos com a pele ou roupa molhada.

• Isole-se da peça e terra.

• Keep flammable materials away.

• Mantenga el material combustiblefuera del área de trabajo.

• Gardez à l’écart de tout matérielinflammable.

• Entfernen Sie brennbarres Material!

• Mantenha inflamáveis bem guarda-dos.

• Wear eye, ear and body protection.

• Protéjase los ojos, los oídos y elcuerpo.

• Protégez vos yeux, vos oreilles etvotre corps.

• Tragen Sie Augen-, Ohren- und Kör-perschutz!

• Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

• Keep your head out of fumes.• Use ventilation or exhaust toremove fumes from breathing zone.

• Los humos fuera de la zona de res-piración.

• Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

• Gardez la tête à l’écart des fumées.• Utilisez un ventilateur ou un aspira-teur pour ôter les fumées des zonesde travail.

• Vermeiden Sie das Einatmen vonSchweibrauch!

• Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

• Mantenha seu rosto da fumaça.• Use ventilação e exhaustão pararemover fumo da zona respiratória.

• Turn power off before servicing.

• Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

• Débranchez le courant avant l’entre-tien.

• Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öffnen;Maschine anhalten!)

• Não opere com as tampas removidas.• Desligue a corrente antes de fazerserviço.

• Não toque as partes elétricas nuas.

• Do not operate with panel open orguards off.

• No operar con panel abierto oguardas quitadas.

• N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

• Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

• Mantenha-se afastado das partesmoventes.

• Não opere com os paineis abertosou guardas removidas.

• 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

• World's Leader in Welding and Cutting Products •

FOR ENGINE · 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding...

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Transcript of FOR ENGINE · 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding...