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IM803-B
RED-D-ARC
August, 2006
ES 275i
10994,11166,11223 & 11266
For use with machines having Code Numbers:
RETURN TO MAIN MENU
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
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Table of Contents
Troubleshooting
Related Manuals for Red-D-Arc IM803-B
Summary of Contents for Red-D-Arc IM803-B
- Page 1 For use with machines having Code Numbers: RETURN TO MAIN MENU 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.
- Page 2 SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm.
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Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
- Page 6 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.
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Page 7: Table Of Contents
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 ________________________________________________________________________________... -
Page 8: Installation
INSTALLATION Technical Specifications - ES 275i INPUT AT RATED OUTPUT - THREE PHASE ONLY OUTPUT INPUT Idle Efficiency INPUT VOLTS-Hz CONDITIONS CURRENT Power @ Rated AMPS Output 150W Max 200A@28V.100% 27/25/13/11 208/230/460/575V - 60Hz. 250A@30V. 60% 34/33/17/14 275A@31V. 35% 38/37/19/16 25/15/15/14/13 200A@28V.100% 220/380/400/415/440 - 50Hz... -
Page 9: Safety Precautions
INSTALLATION TILTING Read this entire installation section before you Place the machine directly on a secure, level surface. start installation. The machine may topple over if this procedure is not SAFETY PRECAUTIONS followed. HIGH FREQUENCY PROTECTION WARNING Locate the ES 275i away from radio controlled ELECTRIC SHOCK machinery. -
Page 10: Input Voltage Reconnect Procedure
INSTALLATION INPUT VOLTAGE RECONNECT OUTPUT CONNECTIONS PROCEDURE Refer to figure B.1 for the location of the 3-Pin Remote Receptacle and the Output Terminals. When received directly from the factory, units are con- nected for, 460 VAC. If 460 VAC is the desired input, OUTPUT CABLES then the machine may be connected to the power sys- tem without any setup required inside the reconnect... -
Page 11: Operation
OPERATION Read and understand this entire section before GENERAL DESCRIPTION operating your machine. The ES 275i is a 275 amp arc welding power source SAFETY PRECAUTIONS that utilizes single or three phase input power, to pro- duce constant current output. The welding response WARNING of this Invertec has been optimized for stick (SMAW) and TIG (GTAW). -
Page 12: Controls And Settings
OPERATION 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. LOCAL REMOTE OUTPUT HOT START ARC FORCE CC STICK REMOTE 1. -
Page 13: Constant Current Processes
OPERATION 7. OUTPUT TERMINALS - These quick discon- nect terminals are compatible with TWECO®* con- nectors. The terminal provide connection points for Note: The short circuit current is limited to 20 amps to the electrode and work cables. Refer to Output aid in touch starting. -
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
MAINTENANCE 4. Obtain a high resistance and high wattage resistor WARNING (25-1000 ohms and 25 watts minimum). This resis- ELECTRIC SHOCK can kill. tor is not supplied with machine. NEVER USE A • Have an electrician install and service SHORTING STRAP FOR THIS PROCEDURE. this equipment. -
Page 16: Routine Maintenance
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
MAINTENANCE FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. WRAP-AROUND CENTER ASSEMBLY COOLING FANS OUTPUT RECTIFIER ASSEMBLY CASE FRONT ASSEMBLY INPUT RECTIFIER CONTROL PC BOARD CASE BACK ASSEMBLY MAIN TRANSFORMER ASSEMBLY POWER SWITCH OUTPUT TERMINALS CHOKE ASSEMBLY SWITCH BOARD & HEAT SINK ASSEMBLY BASE ES 275i... -
Page 18: Troubleshooting
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. -
Page 19: Pc Board Troubleshooting Procedures
TROUBLESHOOTING & REPAIR PC BOARD TROUBLESHOOTING PROCEDURES - Remove the P.C. Board from the static- WARNING shielding bag and place it directly into the ELECTRIC SHOCK can kill. equipment. Don’t set the P.C. Board on or Have an electrician install near paper, plastic or cloth which could have and service this equip- a static charge. - Page 20 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is observed when cover wrap-around is removed. The machine is dead - no output. 1. The input power switch must be in the ON position.
- Page 21 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS Output turns on momentarily, then 1. Check the input voltages and switches off and repeats cycle. reconnection procedures. Make sure the input voltage is correct for the machine.
- Page 22 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS No output - Main input fuses open, 1. Inspect input leads for possible indicating excessive current draw. shorts or grounds or mis-connec- tions.
- Page 23 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION OUTPUT PROBLEMS The machine will not produce more 1. This may be normal operation. If than 200 amps. the output current exceeds 300 amps, an electronic protection circuit will reduce the current to less than 200 amps.
- Page 24 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION WELDING PROBLEMS Poor welding, weld settings drift, or 1. Make sure the machine settings output power is low. are correct for the weld process being used.
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Page 25: Wiring Diagrams
WIRING DIAGRAMS WIRING DIAGRAM- CODE: 10994 ES 275i... - Page 26 WIRING DIAGRAMS WIRING DIAGRAM- CODE: 11166, 11223 ES 275i...
- Page 27 WIRING DIAGRAMS WIRING DIAGRAM- CODES: 11266 ES 275i...
- Page 28 DIAGRAMS ES 275i...
- Page 29 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 30 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 31 • 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...