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Lincoln Electric IM803-B manual

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Table of contents for the manual

  • Page 1

    RED-D-ARC ES 275i IM803-B August, 2006 Red-D-Ar c Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful oper[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work 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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

  • Page 5

    iv SAFETY iv Mar. ‘93 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. Les[...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Safety Precautions. .........................[...]

  • Page 8

    ES 275i A-1 INST ALLA TION 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 PHASE RECOMMENDED MINIMUM INPUT WIRE AND FUSE SIZES Input Voltage-Hz 208/230-60 460/575-60 22[...]

  • Page 9

    A-2 INST ALLA TION A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. • Be sure to discharge capacitors wit[...]

  • Page 10

    ES 275i OUTPUT CONNECTIONS Refer to figure B.1 for the location of the 3-Pin Remote Receptacle and the Output Terminals. OUTPUT CABLES Select the output cable size based on Table A.1. TABLE A.1 Cable Sizes for Combined Length of Electrode and Work Cable ( Copper Cable Rated at 75°C). Length Cable Size up to 150 ft.(46m) 1/0 (50mm 2 ) up to 250 ft.[...]

  • Page 11

    ES 275i B-1 OPERA TION B-1 GENERAL DESCRIPTION The ES 275i is a 275 amp arc welding power source that utilizes single or three phase input power, to pro- duce constant current output. The welding response of this Invertec has been optimized for stick (SMAW) and TIG (GTAW). OPERA TIONAL FEA TURES The ES 275i provides continuous total range output cu[...]

  • Page 12

    B-2 OPERA TION B-2 1 . POWER SWITCH - Place the lever in the “ON” position to energize the machine. When the power is on the output will be energized in STICK (SMAW) mode and TIG (GTAW) if the remote is set to local control. At power up the thermal Light and Fan will turn on for approxi- mately 3 seconds. 2. OUTPUT CONTROL - This controls the o[...]

  • Page 13

    B-3 OPERA TION B-3 7. OUTPUT TERMINALS - These quick discon- nect terminals are compatible with TWECO®* con- nectors. The terminal provide connection points for the electrode and work cables. Refer to Output Connection in the Installation chapter for proper cable sizes. For positive polarity welding connect the electrode cable to the positive term[...]

  • Page 14

    B-4 OPERA TION B-4 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. Reset occurs when the outp[...]

  • Page 15

    D-1 MAINTENANCE D-1 INPUT FIL TER CAP ACITOR DISCHARGE PROCEDURE 1 . Turn off input power or disconnect input power lines. 2. Remove the 5/16" hex head screws from the side and top of the machine and remove wrap-around machine cover. 3. Be careful not to make contact with the capacitor terminals that are located in the top and bottom of the Po[...]

  • Page 16

    D-2 MAINTENANCE D-2 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 (detai[...]

  • Page 17

    ES 275i D-3 MAINTENANCE D-3 FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. SWITCH BOARD & HEA T SINK ASSEMBL Y CONTROL PC BOARD MAIN TRANSFORMER ASSEMBL Y CHOKE ASSEMBL Y OUTPUT TERMINALS POWER SWITCH CENTER ASSEMBL Y COOLING F ANS CASE BACK ASSEMBL Y CASE FRONT ASSEMBL Y WRAP-AROUND BASE INPUT RECTIFIER OUTPUT RECTIFIER ASSEMBL Y[...]

  • Page 18

    ES 275i E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine[...]

  • Page 19

    ES 275i E-2 TROUBLESHOOTING & REP AIR E-2 _______________________________ CAUTION: Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards, please use the following procedure: 1 . Determine to the best [...]

  • Page 20

    ES 275i E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 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. 1. The input powe[...]

  • Page 21

    ES 275i E-4 TROUBLESHOOTING E-4 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Output turns on momentarily, then switches off and repeats cycle. Remote output control not functioning. The machine operates normally on LOCAL control. 1 . Check the input vol[...]

  • Page 22

    ES 275i E-5 TROUBLESHOOTING E-5 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 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 i[...]

  • Page 23

    ES 275i E-6 TROUBLESHOOTING E-6 Observe all Safety Guidelines detailed throughout this manual OUTPUT PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION The machine will not produce more than 200 amps. 1. This may be normal operation. If the output current exceeds 300 amps, an electronic protection circuit will reduce the curre[...]

  • Page 24

    ES 275i E-7 TROUBLESHOOTING E-7 Observe all Safety Guidelines detailed throughout this manual WELDING PROBLEMS PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 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. 1. [...]

  • Page 25

    F-1 WIRING DIAGRAMS F-1 ES 275i R2 AR C FOR CE WE LD MODE OFF 328 327 304 SMAW GTAW VIEW OF CONNECTOR ON PC BOARD ELECTRICAL SYMBOLS PER E1537. OHMS/WATTS COMPONENT VALUE UNITS: RESISTORS: MFD/VOLTS CAPACITORS: 8 LATCH 0F CONNECTOR J 5 EXAM PLE: THI S IS PIN 7 3 2 LEAD COLORING CODE: B-BLACK 2 1 8 G-GREEN O-ORANGE R-RED CONNECTOR P IN NUMBERS : 7 1[...]

  • Page 26

    F-2 WIRING DIAGRAMS F-2 ES 275i WIRING DIAGRAM- CODE: 1 1 166, 1 1223 R2 AR C FOR CE WE LD MODE OFF 328 327 304 SMAW GTAW VIEW OF CONNECTOR ON PC BOARD ELECTRICAL SYMBOLS PER E1537. OHMS/WATTS COMPONENT VALUE UNITS: RESISTORS: MFD/VOLTS CAPACITORS: 8 LATCH 0F CONNECTOR J 5 EXAM PLE: THI S IS PIN 7 3 2 LEAD COLORING CODE: B-BLACK 2 1 8 G-GREEN O-ORA[...]

  • Page 27

    F-3 WIRING DIAGRAMS F-3 ES 275i WIRING DIAGRAM- CODES: 1 1266 R2 AR C FOR CE WE LD MODE OFF 328 327 304 SMAW GTAW VIEW OF CONNECTOR ON PC BOARD ELECTRICAL SYMBOLS PER E1537. OHMS/WATTS COMPONENT VALUE UNITS: RESISTORS: MFD/VOLTS CAPACITORS: 8 LATCH 0F CONNECTOR J 5 EXAM PLE: THI S IS PIN 7 3 2 LEAD COLORING CODE: B-BLACK 2 1 8 G-GREEN O-ORANGE R-RE[...]

  • Page 28

    F-4 DIAGRAMS F-4 ES 275i 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

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA E[...]

  • Page 30

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes [...]

  • Page 31

    • 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 •[...]