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Lincoln Electric R3R-500 manual

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Table of contents for the manual

  • Page 1

    SVM139-A June 1998 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAUTION[...]

  • Page 2

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY i i IDEALARC R3R FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, wel[...]

  • Page 3

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY ii ii IDEALARC R3R ARC RA YS 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 Z87. I sta[...]

  • Page 4

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iii iii IDEALARC R3R FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and[...]

  • Page 5

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAFETY iv iv IDEALARC R3R PRÉCAUTIONS DE SÛRETÉ Pour votre pr opre protection lir e et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes[...]

  • Page 6

    MASTER T ABLE OF CONTENTS FOR ALL SECTIONS v v IDEALARC R3R Page Safety .................................................................................................................................................i-iv Installation ...................................................................................................................[...]

  • Page 7

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section A-1 Section A-1 IDEALARC R3R T ABLE OF CONTENTS - INST ALLA TION SECTION - Installation ............................................................................................................................. Section A T echnical Specifications, Ideala[...]

  • Page 8

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-2 A-2 IDEALARC R3R TECHNICAL SPECIFICA TIONS - IDEALARC R3R-300 INPUT - THREE PHASE ONL Y Standar d V oltage Input Current @ Rated Output 230V 56A 460V 28A RA T[...]

  • Page 9

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-3 A-3 IDEALARC R3R TECHNICAL SPECIFICA TIONS - IDEALARC R3R-400 INPUT - THREE PHASE ONL Y Standar d V oltage Input Current @ Rated Output 230V 74A 460V 37A RA T[...]

  • Page 10

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-4 A-4 IDEALARC R3R TECHNICAL SPECIFICA TIONS - IDEALARC R3R-500 INPUT - THREE PHASE ONL Y Standar d V oltage Input Current @ Rated Output 230V 88A 460V 44A RA T[...]

  • Page 11

    Read this entire installation section befor e you start installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing. • Insulate yourself fr om the work and ground. • Always wear dry insulating gloves. Only qualified personnel should install, use, or ser- vice th[...]

  • Page 12

    INPUT CONNECTIONS ELECTRIC SHOCK can kill. • Have a qualified electrician install and service this equip- ment. • T ur n the input power off at the fuse box before working on this equipment. • Do not touch electrically hot parts. • Insulate yourself from the work and gr ound. • Always wear dry insulating gloves. Be sure the voltage, phase[...]

  • Page 13

    Have a qualified electrician connect the input power leads to the L1, L2, and L3 terminals of the input con- tactor . Follow all national and local electrical codes. Use a three-phase line. Refer to the connection dia- gram located on the inside of the access panel cover for proper input voltage connection. Also see Figure A.3. INPUT WIRE AND FUSE [...]

  • Page 14

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION A-8 A-8 IDEALARC R3R FIGURE A.3 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOL TS AC, 50/60 HZ THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. 1. TUR[...]

  • Page 15

    The output (welding) cables are connected to the out - put terminals marked “+” and “-”. See T able A.1 for r ecommended cable sizes for the combined lengths of electr ode and work cables. The output terminals ar e located at the lower right and lower left corners of the fr ont panel. Strain r elief for the cables is provided by r outing th[...]

  • Page 16

    NOTES A-10 A-10 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 17

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section B-1 Section B-1 IDEALARC R3R T ABLE OF CONTENTS - OPERA TION SECTION - Operation ............................................................................................................................... Section B Safety Instructions ..................[...]

  • Page 18

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-2 B-2 IDEALARC R3R OPERA TING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS ELECTRIC SHOCK c[...]

  • Page 19

    GENERAL DESCRIPTION The Idealarc R3R is an SCR contr olled constant cur- r ent DC output power sour ce for welding and cutting. The R3R-300 uses a single range potentiometer con- tr ol. The R3R-400 and R3R-500 have separate low and high range controls. The welder’ s unique combi- nation of 3 phase transformer , SCR/Diode bridge rec- tifier , arc [...]

  • Page 20

    CONTROLS AND SETTINGS All operator controls and settings ar e located on the case front assembly . See Figure B.1 for their loca- tions. FIGURE B.1 – CASE FRONT CONTROLS 1. POWER SOURCE PILOT LIGHT : This light indi- cates that input power is applied to the R3R and that the on/off switch is in the ON position. 2. ON/OFF POWER TOGGLE SWITCH: Ener [...]

  • Page 21

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC OPERA TION B-5 B-5 IDEALARC R3R 8. POLARITY SWITCH (optional): Permits chang- ing the electrode polarity of the output terminals between DC+ and DC-. 9. DC AMMETER (optional): D[...]

  • Page 22

    WELDING OPERA TION OPERA TING STEPS LOCAL CONTROL The following procedur es are for using the Idealar c R3R in the local (“R3R”) control mode of operation. For remote contr ol of the machine, see the REMOTE CONTROL section. Befor e operating the machine, make sur e you have all materials needed to complete the job. Be sure you ar e familiar wit[...]

  • Page 23

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ACCESSORIES SECTION - Accessories ........................................................................................................................... Section C Options/Accessories.........................................................[...]

  • Page 24

    OPTIONS/ACCESSORIES F ACTOR Y INST ALLED OPTIONS POLARITY SWITCH Permits changing polarity at the machine output ter- minals. METERS Ammeter and V oltmeter . POCKET AMPTROL Pr ovides a wir eless remote curr ent control for R3R welders. See the Operation section for details. FIELD INST ALLED OPTIONS The following options/accessories are available fo[...]

  • Page 25

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section D-1 Section D-1 IDEALARC R3R T ABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ......................................................................................................................... Section D Safety Precautions.......................[...]

  • Page 26

    SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this mainte- nance. • T ur n the input power OFF at the disconnect switch or fuse box before working on this equipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following daily: 1. Check that no combustible material[...]

  • Page 27

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC MAINTENANCE D-3 D-3 IDEALARC R3R 1 1 12 10 9 8 7 6 5 4 3 2 1 13 FIGURE D.1 – GENERAL COMPONENT LOCA TIONS 1. CONTROL P ANEL 2. SCR/DIODE BRIDGE 3. MAIN TRANSFORMER 4. CHOKE 5.[...]

  • Page 28

    NOTES D-4 D-4 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 29

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section E-1 Section E-1 IDEALARC R3R T ABLE OF CONTENTS - THEOR Y OF OPERA TION SECTION - Theory of Operation ............................................................................................................. Section E General Description ...............[...]

  • Page 30

    GENERAL DESCRIPTION The Idealarc R3R welder is a thr ee-phase transformer r ectifier type constant curr ent power sour ce designed for DC manual welding and air carbon arc cutting. Its power system is SCR controlled with solid state elec - tr onic cir cuitry . Minimum to maximum output is obtained with a single potentiometer control. INPUT LINE VOL[...]

  • Page 31

    OUTPUT RECTIFICA TION, CONTROL, AND FEEDBACK The three-phase AC output fr om the main transformer secondary is rectified and contr olled through the SCR/ diode bridge. Output current and voltage is sensed at the shunt and output terminals. This feedback infor- mation is processed in the contr ol board. The contr ol boar d compar es the commands fro[...]

  • Page 32

    THEOR Y OF OPERA TION E-4 E-4 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE E.4 – OPTIONAL POLARITY SWITCH AND POCKET AMPTROL CIRCUITS CONTROL BOARD OUTPUT CONTROL ARC FORCE CONTROL CONTROL TRANSFORMER [...]

  • Page 33

    PROTECTIVE DEVICES AND CIRCUITS T wo thermostats protect the R3R from excessive operating temperatures and overload conditions. Excess operating temperatures may be caused by insuf ficient cooling air or by operating the machine beyond the duty cycle and output rating. One ther- mostat is mounted on one of the main transformer secondary leads. The [...]

  • Page 34

    SCR OPERA TION A silicon controlled r ectifier (SCR) is a three terminal device used to control rather lar ge currents to a load. An SCR acts very much like a switch. When a gate signal is applied to the SCR, it is turned ON and there is current flow fr om anode to cathode. In the ON state, the SCR acts like a closed switch. When the SCR is turned [...]

  • Page 35

    Retur n to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Section F-1 Section F-1 IDEALARC R3R T ABLE OF CONTENTS - TROUBLESHOOTING & REP AIR SECTION - T r oubleshooting & Repair Section ...................................................................................... Section F How to Use T roubleshooting Gui[...]

  • Page 36

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory T rained Personnel. Unauthorized repairs performed on this equipment may[...]

  • Page 37

    ELECTRIC SHOCK can kill. Have an electrician install and service this equipment. T ur n the machine OFF befor e working on equipment. Do not touch electrically hot parts. Sometimes machine failures appear to be due to PC boar d failur es. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshootin[...]

  • Page 38

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-4 F-4 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 39

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-5 F-5 IDEALARC R3R TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 40

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-6 F-6 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 41

    Return to Section TOC Return to Section TOC Return to Section TOC Retur n to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-7 F-7 IDEALARC R3R TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 42

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-8 F-8 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 43

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-9 F-9 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. CAUTION If for any reason you do not[...]

  • Page 44

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-10 F-10 IDEALARC R3R INPUT CONT ACTOR TEST (FOR MODELS EQUIPPED WITH AC COIL ON INPUT CONT ACTOR) W ARNING Service and repair should be performed[...]

  • Page 45

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-11 F-11 IDEALARC R3R INPUT CONT ACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16?[...]

  • Page 46

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-12 F-12 IDEALARC R3R TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remove the thr ee leads connected [...]

  • Page 47

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-13 F-13 IDEALARC R3R INPUT CONT ACTOR TEST (FOR R3R 300 EQUIPPED WITH DC COIL ON INPUT CONT ACTOR) W ARNING Service and repair should be performe[...]

  • Page 48

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-14 F-14 IDEALARC R3R INPUT CONT ACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16?[...]

  • Page 49

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-15 F-15 IDEALARC R3R TEST FOR CONT ACT CONTINUITY 1. Disconnect the main input supply power to the R3R machine. 2. Remove the two leads connected[...]

  • Page 50

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-16 F-16 IDEALARC R3R W ARNING CONTROL TRANSFORMER (T2) VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory tra[...]

  • Page 51

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-17 F-17 IDEALARC R3R CONTROL TRANSFORMER (T2) VOL T AGE TEST (continued) FIGURE F .5 – CONTROL TRANSFORMER AND LEAD LOCA TIONS TEST PROCEDURE 1[...]

  • Page 52

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-18 F-18 IDEALARC R3R CONTROL TRANSFORMER (T2) VOL T AGE TEST (continued) 6. T est for 115VAC between leads X1 and #231. NOTE: If the main AC inpu[...]

  • Page 53

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-19 F-19 IDEALARC R3R W ARNING MAIN TRANSFORMER (T1) VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory traine[...]

  • Page 54

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-20 F-20 IDEALARC R3R MAIN TRANSFORMER (T1) VOL T AGE TEST (continued) FIGURE F .7 – INPUT CONT ACTOR, RECONNECT P ANEL, AND PRIMAR Y LEADS TO M[...]

  • Page 55

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-21 F-21 IDEALARC R3R 8. Read the meter . a. If proper voltage is pr esent for all three phases, proper main input supply volt- age is being suppl[...]

  • Page 56

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-22 F-22 IDEALARC R3R PHASE ANGLE WINDING TEST 12. T est with an AC voltmeter for approximate- ly 66V AC at each phase winding. T est leads #201, [...]

  • Page 57

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-23 F-23 IDEALARC R3R T ABLE F .1 – PHASE ANGLE WINDING VOL T AGES From Lead # T o Lead # Expected V AC 201 204 66 V AC 202 204 66 V AC 203 204 [...]

  • Page 58

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-24 F-24 IDEALARC R3R W ARNING ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST Service and repair should be performed by only Lincoln Electric factory tr[...]

  • Page 59

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-25 F-25 IDEALARC R3R ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F .11 – CONTROL BOARD G2206 PLUG P4 LOCA TION TEST PROCEDURE 1[...]

  • Page 60

    TROUBLESHOOTING & REP AIR F-26 F-26 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F .14 – RESISTOR R3 LOCA TION FIGURE F .13 – SNUBBER BOARD M15370 PLUG P5 LOCA TION RESISTOR R3 ST A TIC SCR/DIODE[...]

  • Page 61

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-27 F-27 IDEALARC R3R ST A TIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) 7. Remove the red insulating paint fr om the heat sink test points. See[...]

  • Page 62

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-28 F-28 IDEALARC R3R W ARNING ACTIVE SCR TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthor[...]

  • Page 63

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-29 F-29 IDEALARC R3R ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut[...]

  • Page 64

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-30 F-30 IDEALARC R3R ACTIVE SCR TEST (continued) 7. Remove the red insulating paint fr om the heat sink test points. See Figure F .20. NOTE: Do n[...]

  • Page 65

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-31 F-31 IDEALARC R3R W ARNING POCKET AMPTROL CIRCUIT TEST Service and repair should be performed by only Lincoln Electric factory trained personn[...]

  • Page 66

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-32 F-32 IDEALARC R3R POCKET AMPTROL CIRCUIT TEST (continued) TEST PROCEDURE 1. Remove input power to the R3R machine. 2. Using the ohmmeter , che[...]

  • Page 67

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-33 F-33 IDEALARC R3R POCKET AMPTROL CIRCUIT TEST (continued) 8. Connect the Pocket Amptr ol unit from the work to the electrode welding output te[...]

  • Page 68

    TROUBLESHOOTING & REP AIR F-34 F-34 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POCKET AMPTROL CIRCUIT TEST (continued) FIGURE F .23 – SENSING RESISTOR R4 R4 SENSING RESISTOR FIGURE F .24 – POCKET AMPT[...]

  • Page 69

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-35 F-35 IDEALARC R3R This is the typical DC open circuit voltage waveform generated from a properly operating machine. Note that each vertical di[...]

  • Page 70

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-36 F-36 IDEALARC R3R This is the typical DC voltage wave- form generated from a pr operly oper- ating machine. Note that each verti- cal division[...]

  • Page 71

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-37 F-37 IDEALARC R3R This is the typical SCR gate pulse voltage waveform. The machine was in an open circuit condition (no load) and operating pr[...]

  • Page 72

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-38 F-38 IDEALARC R3R This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “GAP” in the waveform. O[...]

  • Page 73

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-39 F-39 IDEALARC R3R W ARNING INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT Service and repair should be performed by only Lincoln Electric factory[...]

  • Page 74

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-40 F-40 IDEALARC R3R INPUT CONT ACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F .25 – INPUT CONT ACTOR CLEANING AND REMOV AL CLEANING PRO[...]

  • Page 75

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-41 F-41 IDEALARC R3R W ARNING F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric facto[...]

  • Page 76

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-42 F-42 IDEALARC R3R F AN MOTOR AND BLADE REMOV AL AND REPLACEMENT (continued) FIGURE F .26 – F AN MOTOR MOUNTING DET AILS PROCEDURE 1. Remove [...]

  • Page 77

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-43 F-43 IDEALARC R3R W ARNING SCR/DIODE RECTIFIER ASSEMBL Y REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Elect[...]

  • Page 78

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-44 F-44 IDEALARC R3R SCR/DIODE RECTIFICER ASSEMBL Y REMOV AL AND REPLACEMENT (continued) FIGURE F .27 – SCR/DIODE ASSEMBL Y DET AILS GLASTIC ST[...]

  • Page 79

    REASSEMBL Y 13. For reassembly , carefully place the SCR/ diode assembly into position on the mounting brackets. 14. Replace and tighten the four nuts and lockwash- ers that hold the SCR/diode assembly to the mounting brackets. 15. Reattach the three heavy aluminum secondary leads and snubber leads to the SCR finned heat sinks. Apply a thin coating[...]

  • Page 80

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-46 F-46 IDEALARC R3R W ARNING SCR REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained person[...]

  • Page 81

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-47 F-47 IDEALARC R3R FIGURE F .28 – SCR DET AILS SCR REMOV AL AND REPLACEMENT (continued) SPECIAL INSTRUCTIONS NOTE: Before disassembling the e[...]

  • Page 82

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-48 F-48 IDEALARC R3R FIGURE F .29 – 1/2” WIDE LEAF SPRING FIGURE F .30 – CLAMP ASSEMBL Y HEX NUT HEA T SINK SCR HEA T SINK HOUSING LEAF SPR[...]

  • Page 83

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-49 F-49 IDEALARC R3R SCR REMOV AL AND REPLACEMENT (continued) CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedur e can only be used wit[...]

  • Page 84

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-50 F-50 IDEALARC R3R SCR REMOV AL AND REPLACEMENT (continued) PROCEDURE FOR THE 5/8 INCH WIDE SPRING 1. Place a piece of sleeving ar ound each ca[...]

  • Page 85

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-51 F-51 IDEALARC R3R CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedur e can only be used with 1/4-28 cap screws. Do not use cap screw[...]

  • Page 86

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-52 F-52 IDEALARC R3R W ARNING MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEA T SINKS Service and repair should be performed by only Lincoln Electri[...]

  • Page 87

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-53 F-53 IDEALARC R3R PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver , remove the case top and sid[...]

  • Page 88

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-54 F-54 IDEALARC R3R W ARNING MAIN TRANSFORMER REMOV AL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory t[...]

  • Page 89

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-55 F-55 IDEALARC R3R REMOV AL OF LIFT BAIL 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver , remove the case[...]

  • Page 90

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-56 F-56 IDEALARC R3R FIGURE F .34 – CHOKE REMOV AL CHOKE BOTTOM "E" IRON GLASTIC STIFFENERS THRU-BOL TS (4) MAIN TRANSFORMER REMOV AL[...]

  • Page 91

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-57 F-57 IDEALARC R3R FIGURE F .35 – EPOXY MIX APPLICA TION AREAS MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) REASSEMBL Y OF TRANSFO[...]

  • Page 92

    3. Install the bottom primary coils, one on each of the thr ee legs of the bottom ir on assembly . The coils must be in correct position (left, center , right). Place the coils so that the leads come out at the back of the machine. See Figure F .36 for proper positioning. 4. Place insulation (Lincoln Electric part number S20728) on top of each of t[...]

  • Page 93

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-59 F-59 IDEALARC R3R MAIN TRANSFORMER REMOV AL & REPLACEMENT (continued) 10. If necessary , trim off excess secondary lead stickout and TIG w[...]

  • Page 94

    REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE NOTE: The following procedur e assumes you have completely reassembled the transformer coils as described in the procedur e above. The lower iron has r emained in place in the machine. See Figures F .26 and F .27. 1. Resolder the choke thermostat lead. 2. Attach the bottom choke lead to the negativ[...]

  • Page 95

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-61 F-61 IDEALARC R3R RETEST AFTER REP AIR (R3R 300) Retest a machine: • If it is r ejected under test for any reason that r equires you to r em[...]

  • Page 96

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-62 F-62 IDEALARC R3R RETEST AFTER REP AIR (R3R 400) Retest a machine: • If it is r ejected under test for any reason that r equires you to r em[...]

  • Page 97

    Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REP AIR F-63 F-63 IDEALARC R3R RETEST AFTER REP AIR (R3R 500) Retest a machine: • If it is r ejected under test for any reason that r equires you to r em[...]

  • Page 98

    NOTES F-64 F-64 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 99

    ELECTRICAL DIAGRAMS G-1 G-1 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams ..............................................................................[...]

  • Page 100

    NOTES G-2 G-2 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 101

    G-3 ELECTRICAL DIAGRAMS R3R Wiring Diagram-R3R-300 ELECTRICAL SYMBOLS PER E1537 LEGEND D5 D6 D7 POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER R1 R2 R3 R4 15 14 13 4 5 6 7 8 9 TO SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE 1 2 3 L1 L2 L3 H3 H2 H1 X2 X1 T2 RECONNECT PANEL SHOWN CONNECTED FOR LOW VOLTAGE 4 5 6 7 8 9 1 2 3 H3 H2 H1 X2 X1 T2[...]

  • Page 102

    G-4 ELECTRICAL DIAGRAMS R3R G-4 Retur n to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC W iring Diagram - R3R-400 (Code 9537) ELECTRICAL SYMBOLS PER E1537 LEGEND D5 D6 D7 POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER R1 R2 R3 R4 [...]

  • Page 103

    G-5 ELECTRICAL DIAGRAMS R3R W iring Diagram - R3R-400 (Code 9874), R3R-500 ELECTRICAL SYMBOLS PER E1537 LEGEND D5 D6 D7 POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER R1 R2 R3 R4 16 TO SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE 1 2 3 L1 L2 L3 ICR 233 232 231 H3 H2 H1 X2 X1 T2 RECONNECT PANEL SHOWN CONNECTED FOR LOW VOLTAGE 4 5 6 7 8 9 1[...]

  • Page 104

    G-6 ELECTRICAL DIAGRAMS R3R Pocket Amptrol Schematic 33.2K R38 X1 14 12 13 Q3 475 R10 68.1K R44 33.2K R39 D9 33.2K R56 1W 12V DZ1 D3 100 50V C4 68.1K R51 15J 50V TP1 33.2K R62 1W 12V DZ2 10.0 R29 D4 10.0 R30 100 50V C5 475 R9 D6 J7 1 133K R13 18 15V C9 1A 100V Q4 4.75K R19 600V .02 C11 J6 1 G Y L G D5 J6 2 50V .68 C10 J7 2 J7 3 3.01K R11 D1 3.01K R[...]

  • Page 105

    G-7 ELECTRICAL DIAGRAMS R3R Snubber Board Schematic & Layout 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED) LM124 (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION = = OP AMPS = DIODES = RESISTORS MFD/VOLTS ON 3 PLACE DECIMALS IS + .OO2 = CAPACITORS ELECTRICAL SYMBOLS PER E1537 J5 6 OHMS,1/4 WATT (UNLESS OTHERWISE SPECIFIED) S NONE SHT. ON HOLES SIZE[...]

  • Page 106

    G-8 ELECTRICAL DIAGRAMS R3R R3R-300 Control PC Board IDENTIFICATION PART No. REQÕD. ITEM R80,R81,R82 R92,R93,R94 R92,R93,R94 QU1,QU2,QU3 C1 C2,C30 C3 C4,C9 C5,C10,C27,C28,C29 C6 .02/600 C11 C18,C19,C20 C21,C22,C23 C31 D1,D2,D3 D4,D5,D6,D7,D8,D9,D10 1N4004 D31,D32,D33 DZ1 DZ2 DZ3 DZ4 DZ5,DZ6,DZ7,DZ8 DZ9 R1,R2,R3 R4,R5,R6,R7,R8,R9 R10,R29,R52 R11,R4[...]

  • Page 107

    G-9 ELECTRICAL DIAGRAMS R3R R3R-400 Control PC Board IDENTIFICATION PART No. REQÕD. ITEM R80,R81,R82 R101,R102,R103 R92,R93,R94 R92,R93,R94 QU1,QU2,QU3 R17,R18,R47,R89 C1 C2,C30 C3 C4,C9 C5,C10,C27,C28,C29 C6 .02/600 C11 C18,C19,C20 C21,C22,C23 C31 D1,D2,D3 D4,D5,D6,D7,D8,D9,D10 1N4004 D31,D32,D33 DZ1 DZ2 DZ3 DZ4 DZ5,DZ6,DZ7,DZ8 DZ9 OCI1 OCI2,OCI3[...]

  • Page 108

    G-10 ELECTRICAL DIAGRAMS R3R R3R-500 Control PC Board IDENTIFICATION PART No. REQÕD. ITEM R80,R81,R82 R101,R102,R103 R92,R93,R94 R92,R93,R94 QU1,QU2,QU3 R17,R18,R47,R89 C1 C2,C30 C3 C4,C9 C5,C10,C27,C28,C29 C6 .02/600 C11 C18,C19,C20 C21,C22,C23 C31 D1,D2,D3 D4,D5,D6,D7,D8,D9,D10 1N4004 D31,D32,D33 DZ1 DZ2 DZ3 DZ4 DZ5,DZ6,DZ7,DZ8 DZ9 OCI1 OCI2,OCI[...]