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

Page 1: ...es having Code Numbers 10994 11166 11223 11773 The Global Leader in Welder Rentals OPERATOR S MANUAL RED D ARC ES 275i IM803 C February 2011 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 ...

Page 2: ...AKER WEARERS ShOuLD CONSuLT WITh ThEIR DOCTOR bEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is ava...

Page 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...riés 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 Elo...

Page 6: ...______________________ Date Purchased___________________________________________________________________________ Where Purchased_________________________________________________________________________ Whenever you request replacement parts or information on this equipment always supply the information you have recorded above CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing ...

Page 7: ...peration B 3 Overload Protection B 4 Thermal Protection B 4 Fan B 4 Power Up Sequence B 4 ________________________________________________________________________________ Maintenance Section D Input Filter Capacitor Discharge Procedure D 1 Routine Maintenance D 2 Filter Capacitor Conditioning D 2 Location of Maintenance Components D 3 _______________________________________________________________...

Page 8: ... 400 415 440 50Hz INPuT CuRRENT AMPS 27 25 13 11 34 33 17 14 38 37 19 16 25 15 15 14 13 32 20 19 18 17 Idle Power 150W Max Idle Power 150W Max Efficiency Rated Output 87 Efficiency Rated Output 87 OuTPuT CONDITIONS 200A 28V 100 250A 30V 60 275A 31V 35 200A 28V 100 250A 30V 35 INPuT AT RATED OuTPuT SINGLE PhASE ONLY INPuT VOLTS hz 208 230 460 575V 60Hz 220 380 400 415 440 50Hz INPuT CuRRENT AMPS 55...

Page 9: ...the machine directly on a secure level surface The machine may topple over if this procedure is not followed hIGh FREQuENCY PROTECTION Locate the ES 275i away from radio controlled machinery 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 the equipment INPuT CONNECTIONS The ES 275i should be connected...

Page 10: ...ns below Failure to follow these instructions can cause immediate failure of components within the welder 1 Open the access door on the left side of the machine 2 For 208 230 Position the large switch to 208 230 For 380 575 Position the large switch to 380 575 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 ...

Page 11: ...MITATIONS The ES 275i is not recommended for pipe thawing Read and understand this entire section before operating your machine SAFETY PRECAuTIONS 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 ____________________________________ __________________________________...

Page 12: ...tick welding Output energized when machine is on TIG GTAW Optimized for touch start use Short circuit current is limited to approximately 20 amps to aid in touch starting 5 hOT START Controls the amount of starting ener gy in CC Stick SMAW The Hot Start can be either turned on or off When on it provides a striking current at 260 of the set current or 275A whichever is larger then quickly reverts t...

Page 13: ...le 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 ...

Page 14: ...ating the machine beyond the duty cycle and output rating If excessive operating temperature should occur the thermostats will prevent output voltage or current Thermostats are self resetting once the machine cools sufficiently FAN The cooling fan on the ES 275i operates once 15 amps of welding current is drawn and for 7 minutes after the output current has stopped flowing The fan will also run an...

Page 15: ...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 r...

Page 16: ...ctifier 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 in good condition to ensure that high voltage parts are protected and correct spacings are maintained All external sheet metal screws must be in place to assure case strength and ...

Page 17: ...WER SWITCH CENTER ASSEMBLY COOLING FANS CASE BACK ASSEMBLY CASE FRONT ASSEMBLY WRAP AROUND BASE INPUT RECTIFIER OUTPUT RECTIFIER ASSEMBLY 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 ...

Page 18: ...labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Authorize...

Page 19: ...om the static shielding bag and place it directly into the equipment Don t set the P C Board on or near paper plastic or cloth which could have a static charge If the P C Board can t be installed immediately put it back in the static shielding bag If the P C Board uses protective shorting jumpers don t remove them until installation is complete If you return a P C Board for credit it must be in th...

Page 20: ...jumper are in the proper position for the input voltage being applied Refer to Input Voltage Reconnect Procedure in the Installation Chapter 5 Check continuity of the 0 6 amp slow blow fuse located on the reconnect panel 1 If the machine has not been used for a long time and is connected for 380 VAC or higher the capacitors may need condition ing See Input Filter Capacitor Conditioning 2 The machi...

Page 21: ...e 2 Check or replace remote control device If used 1 Make sure the Local Remote switch S3 is in the REMOTE position 2 The remote control device may be faulty Replace 3 The Local Remote switch must be in the LOCAL position unless a remote control device is attached to the remote receptacle If all recommended possible areas of misadjustment have been checked and the problem persists Contact your loc...

Page 22: ...or grounds or mis connec tions 2 Install new fuses and reapply power If fuses open again con sult a Authorized Field Service Facility 1 Check the input voltage and input voltage reconnect procedures See Installation Section of this manual If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Facility If for any rea...

Page 23: ... current until the protection circuit is reset Reset occurs when the output load is removed 2 Check the input voltage and input voltage reconnect procedures See Input Voltage Reconnect Procedure 3 Check for loose or faulty welding cables If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Facility If for any reas...

Page 24: ... of this manual 4 Check for loose or faulty welding cables 1 Check for loose or faulty welding cables 2 Is the electrode DRY Try weld ing with another electrode from a different container Make sure you have the correct electrode for the application 3 Make sure the machine settings are correct for the weld process being used 1 Check the input voltage section 2 Check for blockage of vents which rest...

Page 25: ...ITCHES REAR VIEW SHOWN IN 380 575V POSITION S2A S2B 311 310 308 313 307 309 1 4 2 7 8 6 5 3 204 205 C1 C2 SWITCH BOARD CAPACITORS 2200 500 C3 C4 OUTPUT BY PASS CAPACITORS 05 600 CR1 FAN RELAY COIL 12V DC D1A D1B OUTPUT DIODE D2A D2B OUTPUT DIODE D3A D3B OUTPUT DIODE D4 INPUT RECITIER BRIDGE L1 L2 OUTPUT REACTOR L3 OUTPUT INDUCTOR CHOKE L4 L5 RF TOROID CHOKES R1 OUTPUT CONTROL POTENTIOMETER 10K 2 R...

Page 26: ...207 PRIMARY RECONNECT SWITCHES REAR VIEW SHOWN IN 380 575V POSITION S2A S2B 311 310 308 313 307 309 1 4 2 7 8 6 5 3 204 205 C1 C2 SWITCH BOARD CAPACITORS 2200 500 C3 C4 OUTPUT BY PASS CAPACITORS 05 600 CR1 FAN RELAY COIL 12V DC D1A D1B OUTPUT DIODE D2A D2B OUTPUT DIODE D3A D3B OUTPUT DIODE D4 INPUT RECITIER BRIDGE L1 L2 OUTPUT REACTOR L3 OUTPUT INDUCTOR CHOKE L4 L5 RF TOROID CHOKES R1 OUTPUT CONTR...

Page 27: ...reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 28: ...85 20 25 3 17 MAX 79 MIN 88 25 7 00 16 84 2 08 4 30 MAX RECONNECT DOOR OPEN 1 25 O 93 O 15 89 35 TYP 1 44 L11981 A 02 9 00 11 85 20 25 3 17 MAX 79 MIN 88 25 7 00 16 84 2 08 4 30 MAX RECONNECT DOOR OPEN 1 25 O 93 O 15 89 35 TYP 1 44 DIMENSION PRINT ...

Page 29: ...NOTES ES 275i ...

Page 30: ... electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 31: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 32: ...s 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 ...