Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
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 d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour So...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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...
Page 7 - TABLE OF CONTENTS
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 8 - INSTALLATION; PHYSICAL DIMENSIONS; Technical Specifications - ES 275i; INPUT AT RATED OUTPUT - THREE PHASE ONLY
ES 275i A-1 INSTALLATION 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...
Page 9 - SAFETY PRECAUTIONS
A-2 INSTALLATION A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Have an electrician install and service this equipment. • Turn the input power off at the f u s e b o x b e f o r e w o r k i n g o nequipment. • Do not touch electr...
Page 10 - OUTPUT CONNECTIONS; OUTPUT CABLES; Cable Sizes for Combined Length of Electrode and; RECONNECT PROCEDURE; Figure A.1 Input Voltage Reconnect Instructions; CAUTION
ES 275i OUTPUT CONNECTIONS R e f e r t o f i g u r e B . 1 f o r t h e l o c a t i o n o f t h e 3 - P i nRemote 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 Ra...
Page 11 - OPERATION; GENERAL DESCRIPTION; OPERATIONAL FEATURES; ELECTRIC SHOCK can kill.
ES 275i B-1 OPERATION B-1 GENERAL DESCRIPTION The ES 275i is a 275 amp arc welding power sourcethat utilizes single or three phase input power, to pro-duce constant current output. The welding responseof this Invertec has been optimized for stick (SMAW)and TIG (GTAW). OPERATIONAL FEATURES The ES 275...
Page 12 - L O C A L / R E M O T E S W I T C H; CONTROLS AND SETTINGS
B-2 OPERATION B-2 1. POWER SWITCH - Place the lever in the “ON” position to energize the machine. When the power is onthe output will be energized in STICK (SMAW) mode andTIG (GTAW) if the remote is set to local control. At powerup the thermal Light and Fan will turn on for approxi-mately 3 seconds....
Page 13 - Output; T H E R M A L S H U T D O W N I N D I C ATO R; Thermal Protection; CONSTANT CURRENT PROCESSES; AIR CARBON ARC CUTTING*; Note; PARALLEL OPERATION
B-3 OPERATION B-3 7. OUTPUT TERMINALS - These quick discon- nect terminals are compatible with TWECO®* con- nectors. The terminal provide connection points forthe electrode and work cables. Refer to Output Connection in the Installation chapter for proper cable sizes. For positive polarity welding c...
Page 14 - OVERLOAD PROTECTION; THERMAL PROTECTION
B-4 OPERATION B-4 OVERLOAD PROTECTION The machine is electrically protected from producingh i g h o u t p u t c u r r e n t s . S h o u l d t h e o u t p u t c u r r e n texceed 300A, an electronic protection circuit willreduce the current to less than 200A. The machinewill continue to produce this ...
Page 15 - MAINTENANCE; ELECTRIC SHOCK; FIGURE D.1 — LOCATION OF INPUT FILTER CAPACITOR TERMINALS.
D-1 MAINTENANCE D-1 INPUT FILTER CAPACITORDISCHARGE 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-aroundmachine cover. 3. Be careful not to make contact with the capacitor terminals that...
Page 16 - ROUTINE MAINTENANCE
D-2 MAINTENANCE D-2 ROUTINE MAINTENANCE 1. Perform the following preventive maintenance pro- cedures at least once every six months. It is goodpractice 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 i...
Page 17 - FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS.
ES 275i D-3 MAINTENANCE D-3 FIGURE D.2 — LOCATION OF MAINTENANCE COMPONENTS. 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 RECTIFI...
Page 18 - TROUBLESHOOTING; Local Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
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 provi...
Page 19 - TROUBLESHOOTING & REPAIR; PC BOARD TROUBLESHOOTING PROCEDURES
ES 275i E-2 TROUBLESHOOTING & REPAIR E-2 _______________________________ C A U T I O N : S o m e t i m e s m a c h i n e f a i l u r e s appear to be due to PC board failures. Theseproblems can sometimes be traced to poore l e c t r i c a l c o n n e c t i o n s . T o a v o i d p r o b l e m sw ...
Page 20 - OUTPUT PROBLEMS
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 damageis observed when cover wrap-aroundis removed. The machine is dead - no output. No output bu...
Page 22 - Installation Section
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 normallywhen connected for 200 - 230...
Page 23 - Input Voltage Reconnect
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 morethan 200 amps. 1. This may be normal operation. If the output current exceeds 300a m p s , a ...
Page 24 - WELDING PROBLEMS; Installation
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, oroutput power is low. Poor stick electrode welding performance. The arc pops out. The the...
Page 26 - WIRING DIAGRAMS; IRI
F-2 WIRING DIAGRAMS F-2 ES 275i WIRING DIAGRAM- CODE: 11166, 11223 R2 AR C F O R C E WE LD MO D E OFF 328 327 304 SMAW GTAW V IE W OF C ONN EC TO R ON PC B O ARD ELEC TRICA L SYMBO LS PER E 1537. OHMS/WAT TS COMPONENT VALUE UNITS : RESIS TORS: MFD/VOL TS CAPACI TORS: 8 LAT CH 0F C ONN EC TO R J 5 E ...
Page 28 - DIAGRAMS; DIMENSION PRINT
F-4 DIAGRAMS F-4 ES 275i L11981 A.02 9.00 11.85 20.25 3.17 MA X .79 M IN .88 .25 7.00 16.84 2.08 4.30 MA X RECONNEC T DOOR OPEN 1.25 O .93 O 15.89 .35 TY P. 1.44 DIMENSION PRINT
Page 29 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
