Lincoln Electric RED-D-ARC ES 275I Operator's Manual

Lincoln electric welder user manual

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RED-D-ARC
For use with machines having Code Numbers:
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.
The Global Leader in Welder Rentals
ES 275i
10994, 11166, 11223, 11773
IM803-C
February, 2011
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Summary of Contents for Lincoln Electric RED-D-ARC ES 275I

  • Page 1 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 ...
  • Page 2: California Proposition 65 Warnings

    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.
  • Page 3 SAFETY...
  • Page 4 SAFETY...
  • Page 5 PRÉCAuTIONS DE SÛRETÉ Pour 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.
  • Page 6 Thank You...
  • Page 7: Table Of Contents

    Installation...Section A Technical Specifications ...A-1 Safety Precautions..A-2 Suitable Location ...A-2 Stacking ...A-2 Tilting...A-2 High Frequency Protection...A-2 Input Connections ...A-2 Input Fuse and Supply Wire ...A-2 Input Supply Connections ...A-2 Power Input Connections ...A-2 Input Voltage Reconnect Procedure ...A-3 Output Connections...A-3 Output Cables ...A-3 ________________________________________________________________________________ Operation...Section b...
  • Page 8: Installation

    Technical Specifications - ES 275i INPuT AT RATED OuTPuT - ThREE PhASE ONLY INPuT VOLTS-hz 208/230/460/575V - 60Hz. 220/380/400/415/440 - 50Hz INPuT AT RATED OuTPuT - SINGLE PhASE ONLY INPuT VOLTS-hz 208/230/460/575V - 60Hz. 220/380/400/415/440 - 50Hz OuTPuT (ThREE AND SINGLE PhASE) WELDING CuRRENT RANGE 5-275 Amps...
  • Page 9: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAuTIONS WARNING ELECTRIC ShOCK • 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. •...
  • Page 10: Input Voltage Reconnect Procedure

    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.
  • Page 11: Operation

    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.
  • Page 12: Controls And Settings

    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. 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.
  • Page 13: Constant Current Processes

    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)
  • Page 14: Overload Protection

    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 pro- tection circuit is reset.
  • Page 15: Maintenance

    WARNING ELECTRIC ShOCK • 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 capaci- tor discharge procedure to avoid elec- tric shock.
  • Page 16: Routine Maintenance

    ROuTINE MAINTENANCE 1. Perform the following preventive maintenance pro- cedures at least once every six months. It is good practice to keep a preventive maintenance record; a record tag attached to the machine works best. 2. Remove the machine wrap-around cover and per- form the input filter capacitor discharge procedure (detail at the beginning of this chapter).
  • Page 17: Location Of Maintenance Components

    FIGuRE D.2 — LOCATION OF MAINTENANCE COMPONENTS. CASE FRONT ASSEMBLY CONTROL PC BOARD POWER SWITCH OUTPUT TERMINALS CHOKE ASSEMBLY CASE FRONT ASSEMBLY CENTER ASSEMBLY COOLING FANS OUTPUT WRAP-AROUND ASSEMBLY RECTIFIER CHOKE ASSEMBLY OUTPUT TERMINALS CONTROL PC BOARD POWER SWITCH MAIN TRANSFORMER ASSEMBLY SWITCH BOARD &...
  • Page 18: Troubleshooting

    hOW TO uSE TROubLEShOOTING GuIDE 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.
  • Page 19: Pc Board Troubleshooting Procedures

    TROubLEShOOTING & REPAIR PC bOARD TROubLEShOOTING PROCEDuRES WARNING ELECTRIC ShOCK can kill. have an electrician install and service this equip- ment. 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.
  • Page 20 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Major physical or electrical damage is observed when cover wrap-around is removed. The machine is dead - no output. No output but the fan operates nor- mally. 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.
  • Page 21 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Output turns on momentarily, then switches off and repeats cycle. Remote output control not functioning. The machine operates normally on LOCAL control. 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.
  • Page 22 Observe all Safety Guidelines detailed throughout this manual 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.
  • Page 23 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) The machine will not produce more than 200 amps. 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. TROubLEShOOTING POSSIbLE CAuSE...
  • Page 24: Welding Problems

    Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Poor welding, weld settings drift, or output power is low. Poor stick electrode welding performance. The arc pops out. The thermal light and fan keep turn- ing on and off. 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.
  • Page 25: Wiring Diagrams

    WIRING DIAGRAM- CODE: 10994 375B 202A 202A 203A 207A WIRING DIAGRAMS SHUNT 203A TRANSFORMER AUXILIARY ES 275i GND1 BOARD SNUBBER...
  • Page 26 WIRING DIAGRAM- CODE: 11166, 11223 375B 202A 202A 203A 207A WIRING DIAGRAMS SHUNT 203A TRANSFORMER AUXILIARY ES 275i GND1 BOARD SNUBBER...
  • Page 27: Electrical Diagrams

    ELECTRICAL DIAGRAMS WIRING DIAGRAM- CODE: 11773 ES 275i...
  • Page 28 DIAGRAMS ES 275i...
  • Page 29 NOTES ES 275i...
  • Page 32 • 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...

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