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T O W DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT ... and thoughtful operation on your part. This welder is designed and built with safety in mind. design specifications by Lincoln Electric. This R S PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful. However, your overall safety can be increased by proper installation Ia e h Tf H d P R e e O - EtD U D yE G T -- D D A R -R l A E e ro A R c p D C b AT e S IN welder is built to n a p Gd e l T s c HO L
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i i 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. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN bE hAzARDOuS. PROTECT YOuRSELF AND OThERS FROM POSSIbLE SERIOuS INJuRY
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ii ii 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” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv 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 specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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v v for selecting one of our QUALITY products. We want you to take pride in operating this product ••• as much pride as we have in Thank You bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of our company is manufacturing and selling high quality welding equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask us for advice or information about their use of our products. We respond to our customers based
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vi vi TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions. ..............................................................................................................A-2 Suitable Location..............................................
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A-1 A-1 INSTALLATION Technical Specifications - ES 275i INPuT AT RATED OuTPuT - ThREE PhASE ONLY INPuT VOLTS-hz Efficiency OuTPuT INPuT Idle @ Rated Output CONDITIONS CuRRENT Power AMPS 200A@28V.100% 27/25/13/11 208/230/460/575V - 60Hz. 250A@30V. 60% 34/33/17/14 150W Max 87% 275A@31V. 35% 38/37/19/16 25/15/15/14/13 200A@28V.100% 220/380/400/415/440 - 50Hz 32/20/19/18/17 250A@30V. 35% INPuT AT RATED OuTPuT - SINGLE PhASE ONLY INPuT VOLTS-hz OuTPuT INPuT Idle Efficiency CONDITIONS CuRRENT Powe
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A-2 A-2 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 followed. SAFETY PRECAuTIONS hIGh FREQuENCY PROTECTION WARNING Locate the ES 275i away from radio controlled ELECTRIC ShOCK can kill. machinery. • have an electrician install and CAuTION service this equipment. The normal operation of the ES 275i may adverse- • Turn the input power off at t
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A-3 A-3 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 Select the output cable size based on Table A.1. door. For other voltages refer to the instructions
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b-1 b-1 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 of this Invertec has been optimized for stick (SMAW) WARNING and TIG (GTAW). ELECTRIC ShOCK can kill. OPERATIONAL FEATuRES • Do not touch electrically live parts such The ES 275i provides continuous total range ou
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b-2 b-2 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. 2 8 10 3 LOCAL REMOTE OUTPUT HOT START 4 ARC FORCE 5 CC STICK ON OFF OFF +10 -10 TIG 6 REMOTE 9 ON 1 OFF 7 1. POWER SWITCh - Place the lever in the “ON” TIG (GTAW) Optimized for touch start use. Short circuit current is limited to approximately 20 amps to aid in touch position to energ
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b-3 b-3 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. Panel output control Connection in the Installation chapter for proper becomes the current limit setting when in cable sizes. For positive polarity welding connect remote control. the electrode cable to the positi
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b-4 b-4 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. Reset occurs when the output load is removed. Note: When TIG welding with the Output Knob at or above 275 Amps the Arc may go out. ThERMAL PROTECTION Thermostats protect the mac
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D-1 D-1 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. • Turn the input power off at the fuse 5. Locate the four capacitor terminals (large hex head box before working on equipment. cap screws) shown in Figure D.1. One pair at the • Do not touch electrically
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D-2 D-2 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). 3. Keeping the machine clean will result in cooler operation and higher reliability. Be sure to clean the followi
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D-3 D-3 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 OUTPUT TE CASE FRONT R CM HIO NK AE LS AS POWER SWITCH SE ASSEMBL MBL CONTROL Y M YAIN PC BOARD TRANSFORMEINPUT R A WRAP-AROUND SBASE S RECTIFIER EMBLY OUTPUT RECTIFIER
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E-1 E-1 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. __________________________________________________________________________ This Troubl
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E-2 E-2 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. If the P.C. Board can’t be ment. Turn the input power installed immediately, put it back in the static- OFF at the fuse box before shielding bag. working
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E-3 E-3 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. 2. Make sure the input voltage is correct for the machine. 3. If the machine is set for single- phase operation, inspect to assure that the WHITE and BLACK le
