Lincoln Electric IM803-B User's Manual
Contents
1. siy Aq 10 ejenooe eq jou y AjUO 104 SI SIUL 310 G G9EVD Vv LESLA Had STOSWAS YILINI 3009 NOWIACO ONIAVH HO SIN3NOdAOO NO JO LOWX4 3HL MOHS LON SIHL 313 18AOO V 40 IHL 8 ke ER vL i lt 8 9 ONY Z SNId HO LOANNOO OL NI G32NVHOSLNI 38 CNY 80 SQV31 Wf 2442224 ICH ATddNS OL SQV3131IHM 8 HOW 1 AINNOD GPUOIOSNNOD 40 7 621 oN 3009 WNOLLWN Yad OL GVSTNASYO LOANNOO LnidNI 3SVHd 374 SI SIHL 7 NOILVH3dO ASLS SINMOHS NOLL NSNI A009 OL 3dv L SHHENNN HOLOANNOO LNdNI 04 NOLLOANNOS 21 viddOUddl NO 3OV Td ON ATddNS OL SQv313LIHM ONY LOANNOO SION TM 3009 TH TWNOLLWN Yad OL 19 NNOO STONIS MOTHA A age ALIHM OV T8 15640161534 amen 9x SUN 3009 2d 2 LNdLNO X2. 4X HAMRIOJSNVHL OV 1nd1no asva 1 yova OV AZE AON LNdLNO f 1 5 9 OV A099 HANHOASN VAL me S3 HOJSNVL asvo 2 9 HANHOASNVEL NIV AVLSOWYSHL 1VLSOWHSHL HNISLVAH HOLIMS 1VISOWHSHL LNdLNO SSHOUMS LOANNOOSY HOLIMS HAMOd zx 52 00 50151834 VOT 1NdLNO J 2101 H313AOLLN3LOd 30H04 PX 2INOL HALANOLNALOd 44 MOLOV3N INdLNO 390188 4311934 9 100 ANER 009 50 SSVd A8 LNdLNO 006 0022 SHOLIOVdVO HOLIMS SH vH ZH LH li NOLLISOd 9 NI NMOHS 2 Let DEE reng MIIA 193NNO23M 9H SH tH ZH LH do Houms ES 9 EI ON o AYTAY m Ny MWy A802 O ZH Ww MOIS 9 0 Gizem D a 8 lt 8 39404 2d
3. y poised si 10 Ag IS 104 eq jou Ajuo e2u98J9j9J 101 S SIUL ALON C G9 vo 1881 STOSWAS 0878 3000 V HO NO HOLO3NNOO 40 1 3HL MOHS LON SIHL 313 WOO V 40 201 HOW sr A ONILOASSY LNOHLIM 39NVHO AVI QI VOS V JO 9 HO SLNANOdNOD 39NIS ON 8 Heeb Yl 8 9 ANY Z SNId HOLOANNOD 017 38 AVI 6068 806 SOVAT LINDUIO ATddNS OL SQv313LIHM 9 30 18 L AANNOD 144443434 2844444 EN 40 1 E z 7 SAONE NO Moss HON of 6H Va CIN 3009 9819713 TNOILVN OL N3349 LOANNOO 3S VHd i NOILVH3dO ASZS 401 SI NMOHS NOLLOANNOD NOLLVINSNI A009 SCIAOUd OL dv GV31 ZNid SI SIHL TIdWvX3 SYSEWNN HOLO3NNOO WIRING DIAGRAMS 10994 F 1 WIRING DIAGRAM CODE SLIOWGAN SHOlSIS3H SUNN IN3SNOdWOS 0344 ALHMM N33H9 9 amen KRACK 3009 Qv31 ALINDYID AAILIA10Hd asv
4. HAM Rr de t D RES BUR 0 SALAD HAY AS PSP HHCH dl aui Jud AAL oig Gail L LINCOLN e 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
5. 0 41 102 b 60 ace 36 80 8 ELE 10 015 va Lu 297 PLM e A 3570 19259 2 0 034 INVHOVIG WIRING DIAGRAM CODES ES 275i DIAGRAMS F 4 18611 2222221 2222222 EA 1 NOISNAWIG RSS e Tay N3d 4000 LO3NNOO3N XVN DEE ES 275i RED D ARC WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja a Aislese del trabajo de tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf
6. Reusable If you don t have a wrist Do Not Destroy 5 touch an unpainted grounded part of the equipment frame Keep touching the frame to prevent static build up Be sure not to touch any electrically live parts at the same time Tools which come in contact with the P C Board must be either conductive anti static or static dissipate Remove the P C Board from 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 f 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 the static shielding bag This will prevent further damage and allow proper failure analy sis 4 Test the machine to determine if the fail ure symptom has been corrected by the replacement PC board NOTE lt is desirable to a spare known good PC board available for PC board trou bleshooting NOTE Allow the machine to heat up so that all electrical components can reach their oper ating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem the original problem does not reap pear by substituting the original boar
7. l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee 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 Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registr
8. Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases used for arc welding can displace air and cause
9. X Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 RED D ARC SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or se
10. este eege A 3 OPO CT Section B EE B 1 General BI feriae ERE B 1 Operational Features iieri ede Leia EO ena edet cu ee B 1 Welding Capability be einen es B 1 Miu 2e EE B 1 Controls and Settings ss B 2 B 3 Constant iiiaae iiaeaa ani aiie asai B 3 Parallel OperatiOM B 3 Overload EE B 4 Thermal Protection Ec deeg B 4 4 Power Up B 4 L EIuzIEuj Section D Input Filter Capacitor Discharge Procedure D 1 Routine Maintenance dta d e D 2 Filter Capacitor Conditioning ss D 2 Location of Maintenance Components D 3 Troubleshooting 0 0 di Section E Safety Precaution S Fed E 1 PC Board Troubleshooting Procedures E 2 Troubleshooting Guide 2 2 1 E 3 thru E 7 Wiring Diagrams and Dimension Print Section F Parts Pages m P 477 Series 1 A 1 INSTALLATION Technical Specifications ES 275i INPUT AT RATED OUTPUT THREE PHASE ONLY 208 230 460 575V 60Hz 22
11. S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entliiftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o exhaust o remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU EUR Ea fE e 24752 else MAS AH PARAH 587E MBH Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m qui
12. current is drawn and for 7 minutes after the output current has stopped flowing The fan will also run anytime the machine has over heated POWER UP SEQUENCE At power up the thermal light and Power light on codes 11164 and above turns on and the fans run for approximately 3 seconds This is the pre charge time for the main capacitors After this time the fans and thermal light turn off and the pre charge relay closes to apply full line power to the capacitors At this time the machine is ready to weld ES 275i HED D ARC 1 D 1 A WARNING 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 Prior to Performing preventative main tenance perform the following capaci tor discharge procedure to avoid elec tric shock INPUT FILTER CAPACITOR 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 Power Board 4 Obtain a high resistance and high wattage resistor 25 1000 ohms and 25 watts minimum This resis tor is not supplied with machine NEVER USE A SHORTING STRAP FOR THIS PROCEDURE Locat
13. hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra RABE ELE OMLMPT APSSAPREBS NTUSHILT FSU e E GUB GH Oa CRM ER e Xe uc a e sis HIE AMI d Qi Quali Y O 1 d o slt AA JS dan Y Jio Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos OA VE U DOMTORRIER THEW EKA e 18 9 Vi S BET eis Ad d s Jo al gh Ad AIX Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF EU OMAR RSR ez 119 Sal HEHA daig 4 Lilly gupay Daun READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER
14. inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an u
15. procedure each machine should be set to deliver approximately 150 amps not 200 amps from one and 100 amps from the other This will minimize nuisance feedback conditions In general more than two machines in par allel will not be effective due to the voltage require ments of procedures in that power range To set machine outputs start with output control pots and arc force pots in identical positions Adjust out puts and arc forces to maintain current sharing while establishing the proper output current ES 275i HED D ARC EM 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 machine from excessive operating temperatures Excessive temperatures may be caused by a lack of cooling air or operating 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
16. 0 380 400 415 440 50Hz INPUT VOLTS Hz OUTPUT CONDITIONS INPUT AT RATED OUTPUT SINGLE PHASE ONLY OUTPUT CONDITIONS 208 230 460 575V 60 2 220 380 400 415 440 50Hz 200A 8 28 1009 250A 30V 60 275A 31V 35 200A 28V 100 250A 30V 35 200A 28V 100 250A 30V 60 275A 31V 35 200A 28V 100 250A 30V 35 INPUT Idle Efficiency CURRENT Power Rated AMPS Output 27 25 1311 150W Max 34 33 17 14 38 37 19 16 25 15 15 14 13 32 20 19 18 17 INPUT CURRENT AMPS Efficiency Rated Output Idle Power 55 48 26 21 150W Max 72 62 33 27 80 70 38 31 48 32 30 29 27 63 42 40 38 36 OUTPUT THREE AND SINGLE PHASE CURRENT RANGE VOLTAGE RECOMMENDED MINIMUM INPUT WIRE AND FUSE SIZES PHASE SINGLE PHASE Input Voltage Hz Cord Size AWG mm2 Fuse Size Input Voltage Hz Cord Size AWG mm2 Fuse Size based on a type 5 SJ SJO Time Delay Fuse based on a type S SJ SJO Time Delay Fuse or SJT Flexible cord Amps or SJT Flexible cord Amps in 30 C Ambient in 30 C Ambient 208 230 60 8 8 4 208 60 4 25 100 460 575 60 14 2 5 230 60 6 16 100 460 575 60 10 6 60 220 50 380 400 415 50 220 50 6 16 100 440 50 380 400 415 50 8 10 60 440 50 10 6 60 PHYSICAL DIMENSIONS Width Weight With Cord Height 13 6in 345mm Handle Folded Down 20 25 in 514mm 9 0 in 229mm 54 5lbs 24 7Kg 21 7 in 551 With Cord Strain Relief TEMPE
17. 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column 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 Authorized Field Service Facility CAUTION 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 Ser
18. 8 1 Hdoldaindino 2000 1 Y 2000 vg amp iravia Aas OQ 109 009 50 SHOLIOVdVO SSVd A8 LNdLNO 005 0022 SHOLIOVAVO HOLIMS 2010 Se M3WHOJSNVHL 61 91 l oze ASZS 08 NI NMOHS 1 9H SH tH ZH LH WEO HOLIMS 9 1 i E vi D 2 Aly Qu lor 0 1 EET A802 O ZH Ww y MOIS 9 0 39404 2d HOLIMS VOS 2d 10HLNOI 017 KE ANdNi M E va PA 1ndino ENER LNOYS 3572 14 653 24 0 034 D I TYL ES 275i F 3 WIRING DIAGRAMS 11266 F 3 Jequunu epoo 1ueuudinbe 10 ueWyedeg 20S eidel si eui j Sjeued einsojoue y jo euo uo y si epoo jejnomaed 10
19. 913 OL AYTI N39 OO 33H SI SIHL 7 NOLLVH3dO ASZS SI NMOHS NOLLO3NNOO NOLLVTINSNI A009 OL Nid 9VL10A LNANI HO NOLLO3NNOO ALWdOUddY NO V1 V 39V Id IN LINOHIO ATddNS OL SQV3T13LIHM 193NNO9 3000 TIVORLLOGT3 NNOLLVN Yad GNNOYD OL OV31N3339 193NNOO 3SVHd TIONIS 304 SLIONGAN SHOLIOVAVO E SL LVM SNWHO N3349 9 80900 HAMOd OH on 1540151535 ama n S LINDH 1 EN A nova D 77 5 9 auo ann S INdINO OV Lnd1no OV A099 1ndNI bd YINWYOASNYYL 2 HANHOASNVEL HANHOASNVEL Me m 1VISOWH3HL 24OHO 1VISOWH3H L3NISV3H HOLIMS HOLOVAN LVLSOWYSHLL XINIS LV3H S3HO IMS LOANNOOSY HOLIMS HAMOd LNdNI 921001 SHOLSISSY 1NdLNO 1Nd1NO 2130 HALANOILNALOd 39404 OW ZMHOL HALINOLLNALOd LNdLNO GIOHOL 44 LNdLNO YOLOWAY LNdLNO 3904
20. CASE FRONT CONTROLS REMOTE OUTPUT gn TIG B REMOTE 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 5 mately 3 seconds 2 OUTPUT CONTROL This controls the output current Control is provided over the entire output range of the power source with 1 turn of the control This control may be adjusted while under load to change 6 power source output When using remote control this function becomes the limit setting 3 LOCAL REMOTE SWITCH Piace in the LOCAL position to allow output adjustment at the machine Place in the REMOTE position to allow output adjustment at remote pot or amptrol In Remote the machine output control pot is the limit setting for remote control 4 MODE SWITCH CC Stick SMAW Use this mode for all stick welding Output energized when machine is on ES 275i TIG GTAW Optimized for touch start use Short circuit current is limited to approximately 20 amps to aid in touch starting HOT START Controls the amount of starting ener gy in CC Stick SMAW The Hot Start can be ei
21. IM803 B RED D ARC EE ES 275i For use with machines having Code Numbers 10994 11166 11223 amp 11266 RED D A IRC Welderentals 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 WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A 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 OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety
22. MOTE normally on LOCAL control position The remote control device may be faulty Replace The Local Remote switch must be in the LOCAL position unless a remote control device is attached to the remote receptacle A CAUTION 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 ES 275i RED D ARC TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE 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 is connected to 380VAC or higher OUTPUT PROBLEMS 1 Inspect input leads for possible shorts or grounds or mis connec tions Install new fuses and reapply power H fuses open again con sult a Authorized Field Service Facility 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely con tact y
23. RATURE RANGES OPERATING TEMPERATURE RANGE STORAGE TEMPERATURE RANGE 20 C to 40 C 40 C to 40 C 16in 406mm Handle Up 1 When operating on these inputs the line cord may need to be changed On 208VAC single phase the 35 duty cycle output rating is 275A 29V ES 275i 2 INSTALLATION 2 Read this entire installation section before you Start installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill an electrician install and Nee 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 with the proce dure outlined in the Maintenance Section of this manual before working in that area of the equipment SELECT SUITABLE LOCATION The ES 275i will operate in harsh environments Even so it is important that simple preventative measures are followed in order to assure long life and reliable operation The machine must be located where there is free cir culation of clean air such that air movement in the back and out the front will not be restricted Dirt and dust that can be drawn into the machine should be kept to a minimum Failure to observe these precautions can result in excessive operating temperatures and nuisance shutdown Keep machine dry Shelter from rain and snow Do not place on wet ground or in puddles A CAUTION DO NOT MO
24. SHOLIOVdVO SSVd A8 Lnd1nO 005 0022 HO LIMS ZU LU gea vea gea vea alavia FOE 2212 moez 770 oe me O ZH v HL MOIS dv 90 301 36 284 38 EE EE 29 S ON 22253 24 0 134 INVHOVIG SNIHIM ES 275i F 2 WIRING DIAGRAMS 11166 11223 WIRING DIAGRAM CODE F 2 Jequunu epoo 104 ueuwyedeg 2911S eu 01 s au y sjeued ainsojoUS y euo uo y pojsed si 10 siu Aq 10 jou U Ajuo 10 SI SIUL 310 v S9EVD LESLA Had STOSWAS 3309 NONWO9 V HO SLN3NOdNOO Od NO YOLOANNOO 40 LOWX4 JHL MOHS LON WV49VIQ CHvOS 3171dA09 V 40 ALITIEV3ONVHOHLNI IHL e lt 21 n 5 9 Z SNId HO LIANNO DU 38 60 CNY 8028 50 31 TN 4444444 AVIS OL SAYIT ALIHM HOV18 Le TONNIA REL CAN PONIEN 3002 3419
25. UNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides STACKING ES 275i s cannot be stacked TILTING Place 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 CAUTION The normal operation of the ES 2751 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 only by a qualified electrician Installation should be made in accordance with all local and national electric codes and the infor mation detailed below INPUT FUSE AND SUPPLY WIRE Refer to the Technical Specifications page at the beginning of this chapter for the proper fuse sizes and supply cable sizes Fuse the input circuit with recommended super lag fuses or delay type circuit breakers Install the proper fuse in the fuse holder in the main disconnect panel INPUT SUPPLY CONNECTIONS Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the rear of the machine Supply line entry provision is i
26. a H h d 9 _ ain asvo ovs asv 3000 WOLZ D IVNOLLN OL GV31N3389 L93NNOO QHSWNHOJSNVHL 24 5 LNdLNO ANIS 1L V3H 1 p EA Ooze NOLLISOd ASZS 08 NI NMOHS MIA ava S3H2JIMS 193NNOO3M 2d 1OHLNOI Atum e M3WHOJSNVMHL 9 9 sH e AYTAY HAMOd 3LIHM HLIM SONN AN OV LNd1NO OV LNdLNO 9 OV A099 LNANI LNIHHNO HAWHOASNVEAL HAWHOASNVEL AVLSONHAHL 1VLSOWHAHL MNIS1V3H HILIMS LVLSONHAHL XNISLV3H SLL 1Nd1NO LO3NNOO3H HOLIMS 1 92 001 SHO LSIS3H LNd LNO Sint H313AOLLN3 LOd 39H04 MALAWOILNALOd 1OHLNO9 1Nd1NO GIOHOL 44 LNd1NO LAdLNO 43111934 LNdNI LAdLNO 1 41 0 1Nd1NO ASE 102 009 50
27. ation Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page IS ELLE Li Section Technical Specifications sn A 1 REIN 2 Suitable Location 2 ei UM MI ES A 2 ee US A 2 High Frequency Protection 2 Input Connections 2 Input Fuse and Supply Wire sise A 2 Input Supply Connections iii A 2 Power Input A 2 Input Voltage Reconnect Procedure sir A 3 Output A 3 ei
28. d then the PC board was not the problem Continue to look for bad connections in the control wiring har ness junction blocks and terminal strips b If the original problem is recreated by the substitution of the original board then the PC board was the problem Reinstall the replacement PC board and test the machine 6 Always indicate that this procedure was followed when warranty reports are to be submitted NOTE Following this procedure and writing on the warranty report INSTALLED AND SWITCHED PC BOARDS TO VERIFY PROBLEM will help avoid denial of legitimate PC board warranty claims E 3 TROUBLESHOOTING E 3 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 The input power switch must be in the ON position Make sure the input voltage is correct for the machine If the machine is set for single phase operation inspect to assure that the WHITE and BLACK leads are connected properly and the RED lead is not connected and is insulated Check that the input voltage set If all recommended possible areas of up switch and jumper A the misadjustment have been checked reconnect auxiliary jumper are inJand the problem persists Contact voltage being applied Refer to Input Voltage Recon
29. e the four capacitor terminals large hex head cap screws shown in Figure D 1 One pair at the top and one pair at the bottom of the Power Board Use electrically insulated gloves and insulated ers Hold body of the resistor and connect resistor leads across the two capacitor terminals Hold resistor in place for 10 seconds DO NOT TOUCH CAPACITOR TERMINALS WITH YOUR BARE HANDS Repeat discharge procedure for the capacitor on other two terminals 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 remains repeat this capacitor discharge procedure FIGURE D 1 LOCATION OF INPUT FILTER CAPACITOR TERMINALS POWER BOARD UPPER CAPACITOR TERMINALS LOWER CAPACITOR TERMINALS POWER RESISTOR INSULATED PLIERS INSULATED GLOVES ES 275i RED D ARC 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 high
30. er reliability Be sure to clean the following areas with a low pressure air stream See figure D 2 for component locations Power and control printed circuit boards Power switch Main transformer Input rectifier 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 electrical ground continu ity 6 Check electrical ground continuity Using an ohm meter measure resistance between either output terminal and an unpainted surface of the machine case See Figure D 2 for locations Meter reading should be 500 000 ohms or more If meter reading is less than 500 000 ohms check for electrical com ponents that are not properly insulated from the case Correct insulation if needed 7 Replace machine cover and screws ES 275i Wir HED D ARC D 3 MAINTENANCE D 3 FIGURE D 2 LOCATION OF MAINTENANCE COMPONENTS WRAP AROUND CENTER ASSEMBLY COOLING FANS 2 OUTPUT 7 RECTIFIER ASSEMBLY INPUT RECTIFIER CASE BACK ASSEMBLY OUTPUT TERMINALS CHOKE ASSEMBLY SWITCH BOARD amp HEAT SINK ASSEMBLY BASE ES 275i Wir RED D ARC E
31. ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la mas
32. gs output power is low are correct for the weld process being used Check machine performance on LOCAL control If OK then the remote control device may be faulty Check or replace Check the input voltages and input voltage reconnect procedures See Installation Section of this manual Check for loose or faulty welding cables H all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Poor stick electrode welding Check for loose or faulty welding Facility performance The arc pops out cables Is the electrode DRY Try weld ing with another electrode from a different container Make sure you have the correct electrode for the application Make sure the machine settings are correct for the weld process being used The thermal light and fan keep turn 1 Check the input voltage section ing on and off Check for blockage of vents which restricts air flow into or out of the machine CAUTION 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 ES 275i RED D ARC F 1 epoo 1ueuudinbe e 104 jueunredeg eorues 01 9 ejqiGe si au j sjeued einsoj oue euo uo
33. he 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 Cable Size up to 150 ft 46m 1 0 50mm up to 250 ft 72m 2 0 70mm RECONNECT PROCEDURE WARNING 1 SURE POWER SWITCH IS OFF 2 CONNECT LEAD A TO DESIRED INPUT VOLTAGE RANGE 5754 440 460V 2 380 415V s2 220 230V 208V ELECTRIC SHOCK CAN KILL Disconnect input power before inspecting or servicing machine Do not operate with wraparound removed Do not touch electrically live parts Only qualified persons should install use or service this equipment IF MACHINE CEASES TO OPERATE NO METER NO FAN AND THERE 5 NO OTHER KNOWN FAILURE CHECK FUSE REPLACE WITH SPECIFIED FUSE 3 POSITION SWITCH TO DESIRED INPUT VOLTAGE RANGE SIE Lo Figure 1 Input Voltage Instructions ES 275i Re B 1 OPERATION B 1 Read and understand this entire section before operating your machine SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Do 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 be dangerous Keep your head out of fumes e Use vent
34. highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard 249 1 from the American Welding Society P O 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 9 1 1 To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current c
35. ilation or exhaust to remove fumes from breathing zone GOUGING SPARKS can cause fire or explosion Ge Keep flammable material away Do not weld cut or gouge on contain ers that have held combustibles 4 5 burn L Wear eye ear and body protection Only qualified personnel should operate this equip ment Observe all safety information throughout this manual 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 TIG GTAW OPERATIONAL FEATURES The ES 275i provides continuous total range output current adjustment selectable welding modes and local or remote output control Welding characteristics can be controlled via an arc force control Additionally starting characteristics can be adjusted via a hot start control WELDING CAPABILITY The ES 275i is rated at 275 amps 35 duty cycle based on a 10 minute cycle It is also rated at 200 amps 100 duty cycle and 250 amps 60 duty cycle LIMITATIONS The ES 275i is not recommended for pipe thawing ES 275i ED D B 2 OPERATION B 2 CONTROLS AND SETTINGS operator controls and adjustments are located on the case front of the ES 275i Refer to Figure 1 and corre sponding explanations FIGURE B 1
36. injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this 5 f equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b AUG 06 ES RED SAFETY WELDING SPARKS gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances
37. ion 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 diameter carbon rods Output cables an air carbon arc electrode cable 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 is limited to 20 amps to aid in touch starting Panel output control becomes the current limit setting when in remote control Note Operating this machine with the output control set to maximum may cause the machine to phase back and the arc to go out This occurs because the welding current exceeded 300 amps and the machine s protection circuitry activated Turn the output control down to cor rect this condition PARALLEL OPERATION The Invertec s are operable in parallel For best results the currents of each machine should be rea sonably well shared As an example with two machines set up in parallel for a 300 amp
38. ions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t
39. miautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 L 4 b ARC RAYS 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 287 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a
40. n the case rear panel POWER INPUT CONNECTION A 10 ft power cord is provided and wired into the machine Follow the power cord connection instruc tions Incorrect connection may result in equipment damage Single Phase Input Connect green lead to ground per National Electrical Code Connect black and white or brown leads to power Wrap red lead with tape to provide 600V insulation Three Phase Input Connect green lead to ground per National Electrical Code Connect black red and white or brown leads to power ES 275i Re A 3 INPUT VOLTAGE RECONNECT PROCEDURE When received directly from the factory units are con nected for 460 If 460 VAC is desired input then the machine may be connected to the power sys tem without any setup required inside the reconnect door For other voltages refer to the instructions locat ed on the 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 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 INSTALLATION A 3 OUTPUT CONNECTIONS Refer to figure B 1 for the location of the 3 Pin Remote Receptacle and the Output Terminals OUTPUT CABLES Select t
41. na antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas XYVTFFYA 4H EAZKRU D PRE gt e SAUTER Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas SER HGTBI BUSUR RE SERB 430 wel z WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese oe lue chal Gall d arin Mall oe Quad us by pha NM juil ale AREY cuts UI ai Y e Aale Cut Al dl LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SBM BHO X HD OHBRBEE lt K EL TRHOKRERE
42. nect Procedure in the Installation Chapter Check continuity of the 0 6 amp slow blow fuse located on the reconnect panel No output but the fan operates nor 1 If the machine has not been used mally for a long time and is connected for 380 VAC or higher the capacitors may need condition ing See Input Filter Capacitor Conditioning The machine may be overheated Check the thermal indicator light Wait for the machine to cool and the thermostats to reset A CAUTION 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 ES 275i RED D ARC E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION OUTPUT PROBLEMS Output turns on momentarily then f1 Check the input voltages and switches off and repeats cycle reconnection procedures Make sure the input voltage is correct for the machine See Input Voltage Reconnect Procedure Check or replace remote control device If used If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Remote output control not Make sure the Local Remote Facility functioning The machine operates switch S3 is in the RE
43. our local authorized field service facility for technical troubleshooting assistance before you proceed ES 275i RED D ARC E 6 TROUBLESHOOTING E 6 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION OUTPUT PROBLEMS The machine will not produce 1 This may be normal operation than 200 amps the output current exceeds 300 amps an electronic protection circuit will reduce the current to less than 200 amps The machine will continue to produce this low current until the protection circuit is reset Reset occurs when the output load is removed If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Authorized Field Service Check the input voltage and input Facility voltage reconnect procedures See Input Voltage Reconnect Procedure Check for loose or faulty welding cables A CAUTION 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 ES 275i RED D ARC 7 TROUBLESHOOTING E 7 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION WELDING PROBLEMS Poor welding weld settings drift or Make sure the machine settin
44. pright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 Jv RED D ARC SAFETY ii PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instruc t
45. reates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 4 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side
46. se sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher
47. ther 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 to the set current in 0 4 second ARC FORCE This control functions in CC Stick SMAW modes to adjust the Arc Force The arc is soft at the minimum settings and more forceful or driving at the maximum settings Higher spatter levels may be present at the maximum settings Full range is from 10 Soft to 10 Crisp HED D ARC B 3 OPERATION 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 terminal and the work cable to the negative terminal To weld nega tive polarity reverse the electrode and work cables TWECO is registered trademark of Thermo Dyne Corporation 8 THERMAL SHUTDOWN INDICATOR This light will illuminate if an internal thermostat has been activated Machine output will return after the internal components have returned to a normal operating temperature See Thermal Protection later in this Operation chapter 9 3 PIN REMOTE RECEPTACLE 3 Pin remote control allows for remote control of the Output current 10 POWER LIGHT This Light will illuminate when the power switch is in the ON Posit
48. vice Facility for technical troubleshooting assistance before you proceed ES 275i Wir RED D ARC TROUBLESHOOTING amp 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 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 of your technical ability that the PC board is the most likely component causing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is prop erly connected 3 If the problem persists replace the sus pect PC board using standard practices to avoid static electrical damage and electri cal shock Read the warning inside the static resistant bag and perform the follow ing procedures P C Board can be dam aged by static electricity Remove your body s stat ARS ic charge before opening ATTENTION Static Sensitive the static shielding bag Wear an anti static wrist strap For safety use 1 Meg ohm resistive cord connected to a grounded part of the equipment frame Devices only at Static Safe Workstations
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