Red-D-Arc 10994 Operator'S Manual Download 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.  Make sure the machine settings

are correct for the weld process
being used.

2.  Check machine performance on

LOCAL control.  If OK then the
remote control device may be
faulty.  Check or replace.

3.  Check the input voltages and

input voltage reconnect
procedures.  See 

Installation

Section

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 restricts air flow into or out
of the machine.

If all recommended possible areas of
misadjustment have  been checked
and the problem persists, 

Contact

your local Authorized Field Service
Facility.

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.

CAUTION

Summary of Contents for 10994

Page 1: ...wever 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 PRECA...

Page 2: ...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...

Page 3: ...er for 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...

Page 4: ...vent 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...

Page 5: ...appropri s et non inflamma bles 4 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 pais...

Page 6: ...ion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number __________...

Page 7: ...eration B 3 Overload Protection B 4 Thermal Protection B 4 Fan B 4 Power Up Sequence B 4 ________________________________________________________________________________ Maintenance Section D Input Fi...

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 OUTP...

Page 9: ...he 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...

Page 10: ...s 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...

Page 11: ...ITATIONS 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...

Page 12: ...WITCH CC Stick SMAW Use this mode for all stick 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 t...

Page 13: ...e 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 require...

Page 14: ...ting 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...

Page 15: ...onnect 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 o...

Page 16: ...tifier 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 req...

Page 17: ...CE 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 ASSEMBL...

Page 18: ...abeled 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 C...

Page 19: ...m 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 immed...

Page 20: ...umper 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...

Page 21: ...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 i...

Page 22: ...r 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 Se...

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 Chec...

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...

Page 25: ...TCHES 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...

Page 26: ...7 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...

Page 27: ...80 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 D4 INPUT RECITIER BRIDG...

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: ...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...

Page 30: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 31: ...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 Pr...

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