Lincoln Electric ES 275I Welder User Manual


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
-($(#)

)8
R2
ARC FORCE
WELD
MODE
OFF
328
327
3
04
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 J5
EXAMPLE: THIS IS PIN 7
32
LEAD COLORING CODE:
B-BLACK
21
8
G-GREEN
O-ORANGE
R-RED
CONNECTOR PIN NUMBERS:
7
14
U-BLUE
Y-YELLOW
W-WHITE
1
3
J5
R4
G4365-2
A
WIRING DIAGRAM - RED-D-ARC ES275i
ON
HOT
START
Y
THERMAL
+
-
W
B
3
2
6
7
PRI
-O
U
T
PR
I
-I
N
S
E
C
B
O
O
S
T
TP1
INPUT
BRIDGE
_
+
D
E
B
C
F
A
_
POWER SWITCH
W
B
R1
OUTPUT
376
375
377
TP2
TP3
380-
415V
575V
220-
230V
440-
460V
208V
0.6 AMP
SLOW BLOW
S
E
C
B
O
O
S
T
P
RI-
I
N
P
RI
-O
U
T
BASE
CASE
FRONT
PROTECTIVE BONDING CIRCUIT
375B
375B
324
H2
1
8V
U
W
1
303
304A
H1H3H4H5H6
FAN
FAN
CR1
CR1
4
8
0
1
2
6
H1A
6
3524
H2H1H3H4H5H6
H1
H2
H4
H6
H3
H5
H3A
H3A
H3C
H3D
H1D
H1C
H1C
H1B
H1D
FAN RELAY
R
207
209
A1
H1B
A1
A
A
N.C.
209
208
204
201
205
206203A
207A
202A
77
76
75
SWITCH PC BOARD
CONTROL PC BOARD
CASE
BACK
GND2
G
GND1
LINE CORD
208
204
201
205
SHUNT
X4
X2
X4
L1
X2
X7
X8
X5
X6
X1
X3
REACTOR
L2
REACTOR
MAIN
TRANSFORMER
D1A
D1B
D2A
D2B
X7
X6
R
I
G
H
T
L
E
F
T
X8
X
5
X1
X3
OUTPUT RECTIFIER
207A
382
383
3
88
387
REMOTE
RECEPTACLE
SNUBBER PC BOARD
R3
386
385
384
3
81
201
205
204
208
W
R
C2
C1
207A
202A
206
203A
209
R222
W221
L4
L5
CASE FRONT (REAR VIEW)
TP4
C4
C3
TP6
TP5
W
R
T1
T4
T3
AUXILIARY
TRANSFORMER
T
2
D3A
D3B
HEAT SINK
229
376
W
327
324
B
375
303
R(T4)
R(T3)
W(T4)
310
307
308
313
J10
J3
J4
377
328
304
330
1
2
3
4
6
5
1
2
3
4
6
5
7
8
9
10
11
12
309
311
9
8
7
10
387
388
316
320
382
383
229
380
J2
277
76
75
1
2
4
5
8
7
6
12
3
9
R222
W221
1
2
10
11
J1
318
317
S4
L1
L2
L3
L1
L2
L3
(W)
(V)
(U)
W(T3)
S1
D4
J5
B
A
C
380
LOCAL
REMOTE
304A
330
77
277
202
2
06
203A
202
202A
2
03
2
03
207
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,C2SWITCH BOARD CAPACITORS, 2200/500
C3,C4OUTPUT BY-PASS CAPACITORS, .05/600
CR1FAN RELAY COIL, 12V DC
D1A,D1BOUTPUT DIODE,
D2A,D2BOUTPUT DIODE,
D3A,D3BOUTPUT DIODE,
D4INPUT RECITIER BRIDGE
L1,L2OUTPUT REACTOR
L3OUTPUT INDUCTOR (CHOKE)
L4,L5RF TOROID CHOKES
R1OUTPUT CONTROL POTENTIOMETER,10K/2
R2ARC FORCE POTENTIOMETER, 10K/2
R3,R4OUTPUT LOAD RESISTORS, 100/25
S1INPUT POWER SWITCH
S2A,S2BRECONNECT SWITCHES
S3OUTPUT RECTIFIER HEATSINK THERMOSTAT
S4SWITCH BOARD HEATSINK THERMOSTAT
S5CHOKE THERMOSTAT
T1MAIN TRANSFORMER
T2AUXILIARY TRANSFORMER
T3,T4CURRENT TRANSFORMER
TP1,TP2,TP3INPUT MOV, 660V AC
TP4,TP5OUTPUT MOV, 320V AC
TP6OUTPUT MOV, 150V AC
N.E.
NOTES:
N.A. MACHINES WITH RED, BLACK AND WHITE POWER CORDS:
FOR SINGLE PHASE INPUT:CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.
CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT:CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 575V OPERATION.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.
N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6.
L3
OUTPUT
CHOKE
316
S3
318
317
S5
319
320
N.D.
N.D.
N.A.
G
R2
ARC FORCE
WELD
MODE
OFF
328
327
3
04
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 J5
EXAMPLE: THIS IS PIN 7
32
LEAD COLORING CODE:
B-BLACK
21
8
G-GREEN
O-ORANGE
R-RED
CONNECTOR PIN NUMBERS:
7
14
U-BLUE
Y-YELLOW
W-WHITE
1
3
J5
R4
G4365-2
A
WIRING DIAGRAM - RED-D-ARC ES275i
ON
HOT
START
Y
THERMAL
+
-
W
B
3
2
6
7
PRI
-O
U
T
PR
I
-I
N
S
E
C
B
O
O
S
T
TP1
INPUT
BRIDGE
_
+
D
E
B
C
F
A
_
POWER SWITCH
W
B
R1
OUTPUT
376
375
377
TP2
TP3
380-
415V
575V
220-
230V
440-
460V
208V
0.6 AMP
SLOW BLOW
S
E
C
B
O
O
S
T
P
RI-
I
N
P
RI
-O
U
T
BASE
CASE
FRONT
PROTECTIVE BONDING CIRCUIT
375B
375B
324
H2
1
8V
U
W
1
303
304A
H1 H3 H4 H5 H6
FAN
FAN
CR1
CR1
4
8
0
1
2
6
H1A
6
3524
H2H1 H3 H4 H5 H6
H1
H2
H4
H6
H3
H5
H3A
H3A
H3C
H3D
H1D
H1C
H1C
H1B
H1D
FAN RELAY
R
207
209
A1
H1B
A1
A
A
N.C.
209
208
204
201
205
206 203A
207A
202A
77
76
75
SWITCH PC BOARD
CONTROL PC BOARD
CASE
BACK
GND2
G
GND1
LINE CORD
208
204
201
205
SHUNT
X4
X2
X4
L1
X2
X7
X8
X5
X6
X1
X3
REACTOR
L2
REACTOR
MAIN
TRANSFORMER
D1A
D1B
D2A
D2B
X7
X6
R
I
G
H
T
L
E
F
T
X8
X
5
X1
X3
OUTPUT RECTIFIER
207A
382
383
3
88
387
REMOTE
RECEPTACLE
SNUBBER PC BOARD
R3
386
385
384
3
81
201
205
204
208
W
R
C2
C1
207A
202A
206
203A
209
R222
W221
L4
L5
CASE FRONT (REAR VIEW)
TP4
C4
C3
TP6
TP5
W
R
T1
T4
T3
AUXILIARY
TRANSFORMER
T
2
D3A
D3B
HEAT SINK
229
376
W
327
324
B
375
303
R(T4)
R(T3)
W(T4)
310
307
308
313
J10
J3
J4
377
328
304
330
1
2
3
4
6
5
1
2
3
4
6
5
7
8
9
10
11
12
309
311
9
8
7
10
387
388
316
320
382
383
229
380
J2
277
76
75
1
2
4
5
8
7
6
12
3
9
R222
W221
1
2
10
11
J1
318
317
S4
L1
L2
L3
L1
L2
L3
(W)
(V)
(U)
W(T3)
S1
D4
J5
B
A
C
380
LOCAL
REMOTE
304A
330
77
277
202
2
06
203A
202
202A
2
03
2
03
207
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
CR1 FAN RELAY COIL, 12V DC
D1A,D1B OUTPUT DIODE,
D2A,D2B OUTPUT DIODE,
D3A,D3B OUTPUT DIODE,
D4 INPUT RECITIER BRIDGE
L1,L2 OUTPUT REACTOR
L3 OUTPUT INDUCTOR (CHOKE)
L4,L5 RF TOROID CHOKES
R1 OUTPUT CONTROL POTENTIOMETER,10K/2
R2 ARC FORCE POTENTIOMETER, 10K/2
R3,R4 OUTPUT LOAD RESISTORS, 100/25
S1 INPUT POWER SWITCH
S2A,S2B RECONNECT SWITCHES
S3 OUTPUT RECTIFIER HEATSINK THERMOSTAT
S4 SWITCH BOARD HEATSINK THERMOSTAT
S5 CHOKE THERMOSTAT
T1 MAIN TRANSFORMER
T2 AUXILIARY TRANSFORMER
T3,T4 CURRENT TRANSFORMER
TP1,TP2,TP3 INPUT MOV, 660V AC
TP4,TP5 OUTPUT MOV, 320V AC
TP6 OUTPUT MOV, 150V AC
N.E.
NOTES:
N.A. MACHINES WITH RED, BLACK AND WHITE POWER CORDS:
FOR SINGLE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRICAL CODE.
CONNECT BLACK AND WHITE LEADS TO SUPPLY CIRCUIT.
WRAP RED LEAD WITH TAPE TO PROVIDE 600V. INSULATION.
FOR THREE PHASE INPUT: CONNECT GREEN LEAD TO GROUND PER NATIONAL ELECTRIC CODE.
CONNECT BLACK, RED & WHITE LEADS TO SUPPLY CIRCUIT.
N.C. PLACE "A" LEAD ON APPROPRIATE CONNECTION FOR INPUT VOLTAGE.
CONNECTION SHOWN IS FOR 575V OPERATION.
N.B. SINCE COMPONENTS OR CIRCUITRY OF A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING
THE INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT
COMPONENTS OR CIRCUITRY HAVING A COMMON CODE NUMBER.
N.D. CHOKE THERMOSTAT AND LEAD #319 NOT PRESENT ON EARLIER MODELS.
N.E. LEADS #308 AND #309 MAY BE INTERCHANGED IN J10 CONNECTOR PINS 2 AND 6.
L3
OUTPUT
CHOKE
316
S3
318
317
S5
319
320
N.D.
N.D.
N.A.
G
-($(#%
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted
inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
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