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Lincoln Electric IDEALARC R3R-500 User's Manual

1. 5 5 5 to ITEM REQ D PART No IDENTIFICATION lt 1 13490 8 50 25 2 62 630 2 13490 35 50 15 OR 16 9 03 13490 4 022 200 c C4 C9 2 516668 3 100pF 100 EJS C5 010 C27 C28 C29 516668 5 022 50 C6 513490 62 0033 200 7 12 14 15 24 25 26 7 11577 38 02 600 a Ci 513490 73 20 50 C18 C19 C20 3 111577 62 1 200 C21 022 023 3 13490 102 047 100 C3 1577 57 0 1 400 A O vox 9 9 9 01 02 03 3 2199 2 184007 mE D4 D5 D6 D7 D8 D9 D1O _ D11 D12 D13 D14 PEL D24 D28 028 084 038 0 T12199 1 1N4004 ap 031 032 033 3 112199 4 IN4005 5 xil 07 1 2702 23 1N5352B z 072 1 2702 33 1N5347B z 023 1 2702 9 1N5234B e 8 8 al 074 1 2702 40 114735 e 1 025 026 027 028 4 2702 29 1N4744A c 029 1 2702 8 1N5240B 2 2 p gt 2 1 515000 1 4828 8 2 0613 2 515000 5 o z E Q1 Q2 2 112704 69 2N4403 9 r 5 QU1 QU2 QU3 3 1127074 3laz plz 5 5 2 3 12300 73 250 20W ojo 121 R4 R5 R6 R7 R8 R9 6 T14648 12 1500 5W
2. NONE 2 27 91 UNLESS OTHERWISE MFD SCALE DATE 400V CLEVELAND OHIO U S A GENERAL INFORMATION ELECTRICAL SYMBOLS PER CAPACITORS RESISTORS Ohms THE LINCOLN ELECTRIC CO DIODES NOT SHOW THE EXACT COMPONENTS OR CIRCUITRY OF CONTROLS HAVING A COMMON CODE WITHOUT AFFECTING THE INTERCHANGEABILITY OF A COMPLETE BOARD THIS DIAGRAM MAY NUMBER SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NOTES 28 e dg e 2207 NOTE Lincoln Electric assumes no res
3. 5 9 8313 TNOLLdO 04 AINO 431411034 20 6809 lt 30010 425 0 998 9 19 1995 5 5 ZH 09 Ch HOLIMS YMS lt HOLIMS 3019937138 TWIG EMS OLIMS CMS a HOLIMS 80151538 9NISN3S 133904 HO lt 7103109 39H04 104 WHO M0L 1051409 114100 104 WHO X0L S Y31714 114100 Od 2 Lr 3190149 9NISN3S 143004 gt i ANO S3NIHOVM 28 097 YO 002108E NO NO NOLIG3NNCO 93349 34 813 77 0 3931 S db AMV 401 5 Lo 5311801385 1109 45913 ddd S108NAS 19913193713 o WOLLOS NO 5102 007 022 ic 5100 5 OL c IWLSOWHSHL o ABVONOO3S 39089 3010 t 2 2 262 1 MOEZ 03103 00 E NMOHS 13NYd 193NNOO3H Wad ANNOYS OL a SINIT AlddNS OL E3INUOJSNVUL NIVIN 3H L SQV gt 6 6 ONY 8 2 1 SNOILOINNOO 39170 1d39X3 39VLIOA 915 097 HO 009 085 6100 ANN OL zez due 5 1 OL Re 5 D i o m on TYOIMLOIT 39v 10A MOT Q3103NNOO 833 uadwnr
4. OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine SAFETY INSTRUCTIONS WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be 3 dangerous 0 Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire or explosion Keep flammable material away Do not weld on containers that have held com bustibles ARC RAYS can burn Wear eye ear and body protection SN Observe additional Safety Guidelines detailed the beginning of this manual IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC B 3 B 3 OPERATION GENERAL DESCRIPTION The Idealarc R3R is an SCR controlled constant cur rent DC output power source for welding and cutting The R3R 300 uses a single range potentiometer con trol The R3R 400 and 500 have separate low and high range controls The welder s unique combi nation of 3 phase transformer SCR Diode bridge rec tifier arc co
5. HAWHOSSNVHL a NMOHS T3NYd 103NNOO3H ER 040089 OL JHL 1v 30v 3uv OL td SINIT ATddNS 01 5 A086 031238800 OO USNUOASNVUL NIV JHL 1Y NMOHS TANVd 193NNO938 SNOILOSNNOO Sa 6 9 8 9 2 7 SNOLLO3NNOO ABVINIHd o e 6 6 i INVHOVIG 1 009 8 00S 1 008 tc A S a 5 8 5 DOL 4 0 DOL oj 201 191521 0 SOL oj DOL 191521 0 201 201 191521 0 OO uonoeg Return to Section TOC Return to Master TOC Return to Section TOC Ele C 218 5 5 ply a Return to Section TOC Return to Master TOC Return to Master TOC G 6 ELECTRICAL DIAGRAMS Pocket Amptrol Schematic LINCOLN P L6661 FRAME CONNECTION EARTH GROUND CONNECTION SCHEMATIC 9 1 81 4 SUPPLY VOLTAGE NET SUPPLY SOURCE POINT 57 COMMON CONNECTION R3R POCKET AMPTROL SUP S D G TO DIODE HEAT SINK ASSEMBLY SUBJECT 219
6. S3NIHOVIA 919 097 009 086 NO 1 9 91 971 EL 7031409 39404 104 LAdLNO 10d HO MOL HO MOL 831113 LAdLNO 2 399198 ONISNAS 13900 QN3931 45913 334 108IAAS 1991819373 19309 39V 10A 0 51102 AdvINIBd OL 3000 7991810319 amp 3INHOASNVELL YNOLYN JHL LV 30V 0 8 5 6949 SNOLLO3NNOO 3009 1 21810313 TWNOLLVN 834 GNNOHD OL SINIT 14405 OL G 3 Wiring Diagram R3R 300 S109 AUvINIHd OL 1086 03193 02 NMOHS T3NYd 193NNO938 39v L10A TWN M0738 315NIS S7109 OL 3009 191819313 Yad GNNOYS OL Ly 03123 02 Alden OL NMOHS 13NYd 1 3NNO938 915 097 009 086 82 5 51102 veez is for reference only It may not be accurate for all mach 3009 alona 3OVITOA 01 0319309 NMOHS annoia SINIT 19915 OL o DOL 191521 0 001 DOL 1491521 0 201 DOL 1491521 0 201 DOL 191521 0
7. 5 7 7 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS The machine does not have maxi mum output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make sure the correct three phase input voltage is being applied to the machine Make certain the Dial Control Switch SW3 is in the correct position Not present on 300 If the remote control is being used set the Output Control Switch SW2 to the Machine or Local position and control the weld output with the machine Output Control R1 If the problem is resolved check the remote control unit and associ ated cable leads If the Pocket Amptrol option is being used the Pocket Amptrol circuit may be faulty RECOMMENDED COURSE OF ACTION 1 3 Check the Ouptut Check the Output Control R1 Normal resistance is 10 000 ohms Also check associated wiring for loose or faulty con nections See the Wiring Diagram Control Switch S2 and associated wiring See the Wiring Diagram Perform the 4 Perform the SCR Diode Bridge Rectifier Test 5 The control If the Pocket Amptrol is not functioning properly perform the Pocket Amptrol Circuit board may be faulty Replace The machine will not shut off when the power switch is put in the OFF position Make sure the three
8. 1 Return to Section TOC Return to Master TOC Return to Master TOC F 31 TROUBLESHOOTING amp REPAIR POCKET AMPTROL CIRCUIT TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the Pocket Amptrol and associated circuitry is functioning correctly MATERIALS NEEDED Volt ohmmeter 5 16 Nut driver Jumper wires Pocket Amptrol Simplified Drawing This procedure takes approximately 18 minutes to perform IDEALARC R3R LINCOLN P F 31 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC 7 2 32 32 TROUBLESHOOTING amp REPAIR POCKET AMPTRO
9. C 2 9 Accessory Kits K703 70 C 2 on Undercarriages K817P 2 2 2 TIG7Module K990 1 tat chet 2 Water Valve Kit 844 1 C 2 5 Amptrols K870 K812 K963 1 963 2 2 Contactor Kit 9 38 1 2 Docking 9 9 1 Parte Ee 2 Control Cable 936 5 2 Control Cable Extensions K937 22 5 937 45 C 2 0 2 Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 E Return to Section TOC Return to Master TOC gt 2 ACCESSORIES OPTIONS ACCESSORIES FACTORY INSTALLED OPTIONS POLARITY SWITCH Permits changing polarity at the machine output ter minals METERS Ammeter and Voltmeter POCKET AMPTROL Provides a wireless remote current control for R3R welders See the Operation section for details FIELD INSTALLED OPTIONS The following options accessories are available for your Idealarc R3R from your local Lincoln Distributor Remote Current Control K857 Portable cur
10. 232 APPLY EXTERNAL 7 120 232 AND 233A REMOVED us X TEST FOR CONTACT CONTINUITY 1 Disconnect the main input supply power to the R3R machine 2 Remove the two leads connected to the input contactor coil 232 and 2334 3 Using the external 120VDC supply apply 120VDC to the terminals of the input con tactor coil If the contactor does NOT acti vate the input contactor is faulty Replace the input contactor IDEALARC R3R LINCOLN 5 With the contactor activated check the con tinuity across the contacts Zero ohms or very low resistance is normal See Figure 4 If the resistance is high the input con tactor is faulty Replace When the contactor is NOT activated the resistance should be infinite or very high across the contacts If the resistance is low the input contactor is faulty Replace the input contactor 16 16 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason y
11. e A 6 5 Ground 6 5 Input Supply 6 Input Wire and 7 E Reconnect Procedure cancion eite nage tage e ERE LE bae dex o A 8 Output Connections Stick TIG Air Carbon A 9 o 7 2 Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 gt 1 Return to Section TOC Return to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC 300 INPUT THREE PHASE ONLY Standard Voltage Input Current Rated Output 230V 56A 460V 28A RATED OUTPUT Duty Cycle Volts at Rated Amps 10096 29 6096 32 3596 35 OUTPUT Current Range Maximum Open Circuit Voltage 45 to 375 Amps 67 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES 60 DUTY CYCLE Input Wire Size Ground Wire Size Input Voltage Fuse Input Ampere Type 75 C Type 75 C Frequency Super Lag Rating on Copper Wire in Copper Ground or Breaker Size Nameplate Conduit Wire in Conduit Volts Hz AWG IEC Sizes AWG IEC Sizes 230 60 8 10 mm 8 10 mm 460 60 10 6 10 6 mm PHYSICAL DIMENSIONS Height Depth Weight 27 50 in 33 10 in 350 Ibs 700
12. Se i DZ 1 T12702 23 N5352B 022 1 12702 38 53478 023 1 12702 9 52348 074 1 112702 40 4735 075 076 077 078 4 112702 29 4744 079 112702 8 5240 912 Ole OCI2 1 15000 5 b 2 01 02 2 T12704 69 2N4403 g 2 2 5 QU1 QU2 QU3 3 T12707 4 3 L 5 _ 5 2 3 12300 73 250 20W elel 81 R4 R5 R6 R7 R8 R9 6 T14648 12 1500 5W gl TTT I 5 8 810 829 852 3 T10812 67 100K 1 2W 818 811 848 2 19400 1503 E Oc 812 815 821 827 4 _ 519400 2672 13 814 832 835 837 829 80 81 82 9 519400 1003 R16 T10812 62 500 1 2W ed n zc 817 818 847 3 519400 6813 2 54 k R20 19400 4753 E R22 R98 R99 R102 R103 5 _ 519400 1004 ez B B eq R23 R65 R66 R67 110812 30 1 2W e 1710 El R24 81940 6811 E R25 R26 R41 R77 R78 R79 6 19400 4751 Q 5 LOS R28 R45 R74 R75 R76 19400 2213 S S IE 830 831 891 3 114230 23 5 0 MEG OO R33 519400 5622 cla 5 834 895 896 897 4 114231 12 150 1 2W 0912 E p R42 R59 R60 R61 4 1819400 1002 o m EN E 2 838 519400 2673 olg 840 883 884 885 4 619400 2670 o 843 849 2 4231 16 844 886 887 888 4 519400 1001 R46 4231 2 1 2W 85
13. 108 mm IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC 10 5 IDEALARC R3R LINCOLN E A 10 901 J91Se N 01 901 J91Se N 01 UuunjeH 901 J91Se N 01 901 J91Se N 01 201 uonoes DOL uonoes uumeg 201 uonoes DOL uonoes uumeg Section B 1 Section B 1 TABLE OF CONTENTS 5 OPERATION SECTION 2 gt OPS ATOM stunk Section B siia EE B 2 5 Description E 3 Recommended ProceSSes escrios B 3 Design Features and B 3 Welding Capability diiit B 3 GControls and 5 eio rd iE EE erede aa B 4 Welding 6 Operating Steps reris 6 COMMON EEUU 6 Remote Control B 6 HIE 6 Return to Master o 7 2 Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 E Return to Section TOC Return to Master TOC o 7 2
14. 201 LINCOLN E R3R G 4 DEC 97 R3R TO SUPPLY LINES m TO SUPPLY LINES RECONNECT PANEL SHOWN CONNECTED FOR LOW VOLTAGE PRIMARY CONNECTIONS 4 1 6 9 AND 5 8 ARE MADE AT THE MAIN TRANSFORMER RECONNECT PANEL SHOWN RECONNECT PANEL SHOWN CONNECTED FOR 380V TO SUPPLY LINES CONNECTED FOR LOW VOLTAGE TO GROUND TO GROUND PER ELECTRICAL CAL TO GROUND PER NATIONAL ELECTRICAL TO GROU ELECTRICAI CODE X2 CODE DE TO PRIMARY COILS TO PRIMARY COILS 232 SINGLE 346V AND ABOVE EXCEPT 380V TO PRIMARY COILS SINGLE BELOW 346V OR DUAL VOLTAGE TO PRIMARY COILS 380 500 OR 460 575 380V OR TRIPLE VOLTAGE ELECTRICAL SYMBOLS PER E1537 SECONDARY THERMOSTAT 23 LEGEND 13 14 amp 15 ARE PRESENT ON 380 500 OR 460 575 MACHINES ONLY POCKET AMPTROL SENSING BRIDGE DC OUTPUT FILTER 10K OH 10K OH 40 OH 4 OHM POT OUTPUT CONTROL AUXILIARY COILS POT ARC FORCE CONTROL POCKET AMPTROL SENSING RESISTOR TOP PRIMARY THERE IS 10 11 12 POWER SWITCH CONNECTION ON 380 MACHINE REMOTE SWITCH 1 OR TRIPLE VOLTAGE DIAL SELECTOR SWITCH i MACHINES OPTIONAL POLARITY SWITCH 60 Hz ONLY fic to your code is pasted inside one of the enclosure panels of your machine SW4 BOTTOM PRIMARY SCR1 D1 SCR2 D2 SCR3 D3 D4 SCR AND DIODE
15. D 2 General Component LOCATIONS vi iir tcr et oa hr ERE ia eaa Aa Ea D 3 Theory of Operation Section E Troubleshooting and Section F How To Use Troubleshooting Guide 2 gt 4 Test EET 10 Oscilloscope WAVETONINSG eset contiene F 35 Replacement Procedures ii rre este F 39 Retest Ater F 61 Electrical Diagrams oorr Section Parts TEUER 206 IDEALARC R3R LINCOLN Section 1 Section 1 TABLE OF CONTENTS INSTALLATION SECTION Section Technical Specifications Idealarc 300 nennen nnne 2 Technical Specifications Idealarc 400 nnne nennen A 3 Technical Specifications Idealarc 500 nennen nennen 4 Safety 5 Select Suitable asics sede cece 5 MELLE A 5 cH HIM REI A 5 T Em A 5 e Input CONNECTIONS cene
16. F 39 Fan Motor Blade Removal and Replacement sse F 41 SCR Diode Rectifier Assembly Removal and F 43 SCR Removal and F 46 Mounting of Stud Type Diodes to Aluminum Heat 5 F 52 Main Transformer Removal and F 54 Retest After MEE 61 NOTE This manual is based primarily on the model R3R 500 Where tests or other procedures differ sig nificantly for models 300 and R3R 400 those differences are noted 7 2 IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory 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 Electri
17. 8 Inspect the mounting surfaces of each new SCR a Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the SCR mounting surfaces 9 Apply a thin 0 001 to 0 003 layer of PEN ETROX A 13 Lincoln Electric 4E2529 or PENETROX A heat sink compound to each heat sink s SCR mounting surface a Care must be used to prevent foreign material contamination of the SCR to heat sink junction 10 Place the new SCR between the heat sinks Be sure that the outer metal ring of the SCR is facing toward the same heat sink as the old SCR s metal ring Be sure that the roll pin of the heat sink engages the hole in the SCR The SCR contact surfaces must sit flat against both heat sink surfaces IDEALARC LINCOLN 48 48 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE 29 1 2 WIDE LEAF SPRING FIGURE CLAMP ASSEMBLY Return to Section TOC Return to Master TOC SPRING CURVATURE 1 2 lt EXAGGERATED 11 Go to the procedure below that matches your machine s cap screws NOTE WHICH THREAD IS ON YOUR CAP SCREWS BEFORE PROCEEDING TO THE ASSEMBLY PROCEDURE Two different designs of leaf springs and housings have been used to clamp the SCR to the rectifier The two different designs can be identified by the size of the leaf spring One design uses a 1 2 inch wide leaf spring and the other uses a 5 8 inch wi
18. 810 829 852 3 T10812 67 100K 1 2W R11 R48 2 _ 819400 1503 S 812 815 821 827 4 519400 2672 813 814 832 835 837 839 RBO R81 R82 9 19400 1003 4 819 R16 1 0812 62 500 1 2W R17 R18 R47 R89 4 19400 6813 _ E RT9 R20 R22 ROB RO9 R100 5 R101 R102 R103 9 19400 1004 ES R23 R65 R66 R67 4 0812 39 50K 1 2W R24 519400 6811 R25 R26 R41 R77 R78 R79 6 19400 4751 R28 R45 R74 R75 R76 19400 2213 R30 R31 R91 3 4230 23 5 0 MEG R33 19400 5622 2 Eu 25 R34 R95 R96 R97 4 4231 12 150 1 2W oje R36 R42 R59 R60 R61 19400 1002 0 R38 519400 2673 R40 R83 R84 R85 4 19400 2670 ois R48 R49 2 4231 16 olg R44 519400 130 R46 4231 2 10M 1 2W R50 19400 332 ala 851 4231 15 68 5W 853 519400 1501 ojo R54 519400 221 R55 19400 3323 R56 R57 RB8 R62 R63 R64 892 893 894 9 12314 100 1 2W R68 R69 R70 R71 R72 R73 6 1519400 267 R86 R87 R88 519400 100 R90 110812 41 10K 1 2W SCR1 SCR2 SCR3 3 191516119 TP1 TP2 TP8 3 13640 12 38 2 515128 9 Xa 1 515128 4 R92 RO3 R94 CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED NDUCTANCE HENRYS E p 12 218 JE 2 a NOTE Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed
19. Return to Section TOC Return to Master TOC 2A OPEN CIRCUIT VOLTAGES Test Points Input Hertz Open Circuit Volts Welding Output Terminals 60 63 69VDC Welding Output Terminals 50 61 66VDC O10 515 0 gt 8 1 WELDING OUTPUT LOAD TEST Output Control Settings Volts Dial Selector at A 20VDC Maximum Minimum Dial Selector at 43 to 47 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN F 63 F 63 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR 500 Retest a machine e f it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 208 3 60 230 3 60 415 3 60 440 3 60 460 3 60 550 3 60 575 3 60 lk 200 3 50 220 3 50 230 3 50 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 550 3 50 Return to Section TOC Return to Master TOC OPEN CIRCUIT VOLTAGES Test Points Input Hertz Open Circuit Volts Welding Output Terminals 6
20. SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Internal Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 39 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in inspecting cleaning and replacing the input contactor MATERIALS NEEDED Phillips head screwdriver 5 16 socket wrench Flat heat screw driver Low pressure air source 7 16 Socket wrench The contactor cleaning pr
21. gt 58 lt 5 gt E o 2 lt Eo lt Soe qe us a 859 a a 289 22 19 08 4185 WHO 06926 3lVd 5 52 18961 LHS Niw 3108 3349Y 01 32NVH3101 HNN 3NON 396 02 21 _ 338930 Y 30 9 SI STONY TIY NO 5 OILVIN3HOS gt Y S OIHO 1 9902 3 Yad 53215 S310H NO 3420 LLI 00794 09 91819313 JHL onus 9640 101 3sIMH3H1O 5831 6 V3 189615 3INVNdTIJ 223 NOLLO3NNOO NOWWOO A 209 031510399 3SIMH3HLO dO 5 e 031410348 351 10 SSIINN LIOA 530010 031510399 351 10 SS3TNQ L SINHO 580151538 SLIOA GAN SYHOLIOVdVO a 45913 934 108NAS 19919193713 E oo NOILVINHOJNI TVH3N39 LOG o 258 2 0 gla 5 EME Soc gt 5 S E S 298 4 Ul 5 5 o 25 5 2 2 9 2859 8 A o d 2 D S 19687 2 a N 5 1 c 10 901 01 901 J91Se N 01 uunje
22. Polarity etc Check the welding cables for loose or faulty connections Check the input voltage at the R3R making sure the correct voltage and all three phases are being applied to the machine Make sure the welding process is correct for the machine settings Check the welding cables for loose or faulty connections Also make sure the cables are sized correctly for the welding current TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Perform the SCR Diode Rectifier Bridge Test 2 Perform the Main Transformer 3 The control board may be faulty Replace 1 Perform the SCR Diode Rectifier Bridge Test 2 Perform the 3 The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC R3R LINCOLN 10 10 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST FOR MODELS EQUIPPED WITH AC COIL ON INPUT CONTACTOR WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid electrical shock please ob
23. R1 4 ohms 10 watts Ge R2 3 ohms 10 watts gt SCR N UNDER TEST 15 16 17 18 19 20 21 IDEALARC R3R LINCOLN To test SCRs construct the circuit outlined above Resistor values are plus or minus ten percent The voltmeter scale should be low approximately 0 5 or 0 10 volts DC a Ifthe voltage is 3 6 volts while the switch is closed and after the switch is open the SCR is functioning b If the voltage is 3 6 volts only when the switch is closed or if there is no voltage when the switch is closed the SCR is defective NOTE Be sure the battery is function ing properly A low battery can affect the results of the test Repeat Battery Test Procedure in Step 9 if needed Open switch SW 1 Reconnect the tester leads See Figure F 20 a Connect tester lead A to the cathode b Connect tester lead C to the anode c Disconnect test lead G from the gate Close switch SW 1 Read meter for zero voltage a If the voltage is zero the SCR is func tioning b If the voltage is higher than zero the SCR is shorted Perform the Active Test Procedure outlined in Steps 10 18 for SCRs 2 and 3 Replace all SCR assemblies that do not pass the above tests Replace all molex plugs or leads previously removed Resolder lead 204 to resistor R3 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2
24. RECTIFIER BRIDGE iagram speci d MAIN TRANSFORMER CONTROL TRANSFORMER POCKET AMPTROL OPTION TRANSFORMER RECTIFIER BRIDGE iring INPUT STARTER THESE LEADS ARE COLORS PRESENT ONLY WITH A AMBER OPTIONAL METER G GREEN M KIT W WHITE Y YELLOW 3 Lat 13 5 1 08 3 13 20 95 Ex SNUBBER BOARD J7 SNUBBER BOARD DASHED ITEMS ON W DIAGRAM ARE BOARD ELECTRICAL DIAGRAMS i CONTROL tr BOARD UMBERING SEQUENCE ENT SIDE OF BOARD OPTIONAL METER M 205 206 CONNECTOR AND THESE THREE LEADS ARE NOT USED WHEN OPTIONAL POCKET AMPTROL IS PROVIDED SWITCH SHOWN INLOCAL POSITION FRAME GROUND This diagram is for reference only It may not be accurate for all machines covered by this manual The w TE CONTROL RECEPTACLE i o OWNED BY THELINCOLN ELECTRIC ano is ONWOLE SIZES PER THE LINCOLN ELECTRIC __838 400 500 1 500 8 600 1 NOT REPRODUCED DISCLOSED on useD ONS PCE DECIMALS CLEVELAND OHIO U S A WIRING DIAGRAM WITHOUT THE EXPRESS PERMISSION OF ON ALL ANGLES IS 35 or A DEGREE SCALE NONE
25. Return to Section TOC Return to Master TOC 2 49 49 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 4 turn Stop fF Assembly now has the proper clamping force 8 Perform the Active SCR Test CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn STO
26. o THE LINCOLN ELECTRIC CO MATERIAL TOLERANCE TO AGREE care etm oak 159 m 8069 m tc eo tc z I 5 a c 1 5 201 4 0 DOL uonoes DOL 191521 0 001 oj DOL 191521 0 201 DOL 191521 0 201 2 5 5 oc 91561 amp 5 gt 2 Q3diAOud SI 137504 IWNOILdO 5 m N3HM 5 LON SQv31 5 ASSHL HOLO3NNOO 5 o 9 4030151 20 3 035 9NIH3H 5 1902 5 soz s 85 tu ONIHIM NO 03 E lt 91 D 1 LIV 8313W MOTA A o 3389 9 n 0409 4388 y 8 v 5 04 08 um ADM 7 5401009 8 or Te 1 15 1ndNI 13004 190140 gt Uu3AHOJSNvUL 9 J NOlldO 13500 o 3 5 1
27. 4233A and 232A See Figure 4 Connect a DC voltmeter to the leads A WARNING Electric Shock can kill With the input power on there are high volt ages inside the machine Do not reach into the machine or touch any internal part of the machine while the power is on IDEALARC R3R LINCOLN P 5 Apply the correct voltage to the machine and turn the power switch S1 ON Check for approximately 120VDC at the contactor coil leads If the 120VDC IS pre sent at the contactor coil the input contac tor should activate If it does not the input contactor may be faulty Check or replace If the 120VDC is NOT present check for 120VAC at leads 233 and 232 at diode bridge D8 See the Wiring Diagram If the AC voltage IS present but the DC voltage is low or not present the diode bridge may be faulty Check or replace If the 120VAC is NOT present at leads 232 and 233 with the power switch S1 on check the power switch thermostats and associated circuitry See the Wiring Diagram Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC o 7 2 15 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE 4 DC COIL INPUT CONTACTOR TEST POINT LOCATIONS
28. 71423112 150 1 2W 5 6 R36 R42 R59 R60 R61 5 19400 1002 R38 519400 2673 2 x deb R40 R83 R84 R85 4 519400 2670 _ 4 S R43 R49 2 T14281 16 Q 9 LV uS R44 519400 1301 5 R46 1 T14231 2 1 2W x R50 1 519400 3321 R51 1 T14231 15 68 5W R53 519400 1501 R54 1 19400 2211 R55 519400 3323 R56 R57 R58 R62 R63 R64 892 893 894 9 714231 11 100 1 2W R68 R69 R70 R71 R72 R73 6 519400 2671 886 887 888 3 19400 1001 890 1 10812 41 10K 1 2W SCR1 SCR2 8CR3 3 515161 19 TP1 TP2 TP3 3 113640 12 38J 1 2 2 15128 9 1 515128 4 R92 R93 R04 CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 WATT UNLESS OTHERWISE SPECIFIED INDUCTANCE HENRYS E p 212 218 JE 2 NOTE Lincoln Electric assumes responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine R3R
29. Circuit Board Components available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result L ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine R3R G 10 ELECTRICAL DIAGRAMS G 10 R3R 500 Control PC Board 5 ITEM REQ D PART No IDENTIFICATION C1 513490 8 50 25 9 2 30 2 513490 35 50 15 16 o2 13490 4 022 200 2 2 C4 C9 2 16668 3 100pF 100 le 5 10 27 28 29 5 516668 5 022 50 C6 513490 62 0033 200 212 C7 012 C14 C15 024 C25 C26 7 T11577 38 02 600 513490 73 20
30. Ohmmeter Multimeter 5 16 Nut driver Idealarc Wiring Diagrams See the Electrical Diagrams section of this manual This procedure takes approximately 20 minutes to perform Fle 5 0 PEN ele 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 E 7 2 25 25 TROUBLESHOOTING amp REPAIR FIGURE F 11 CONTROL BOARD G2206 PLUG P4 LOCATION R3R CONTROL G2206 Plug P4 Removed TEST PROCEDURE 1 Disconnect the main input supply power to the machine With the 5 16 nut driver remove the case top and sides and lower the front panel Disconnect the welding cables from the welding output terminals Disconnect molex plug P4 from control board G2206 See Figure 11 If the machine has control board G1575 disconnect the individ ual gate leads G1 G2 G3 and also lead 204 See Figure F 12 STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 12 CONTROL BOARD G1575 LEAD LOCATIONS R3R CONTROL G1575 Locate and remove molex plug P5 from snubber board M15370 If the machine has snubber board M14215 label and disconnect Lea
31. R3R LINCOLN F 36 F 36 TROUBLESHOOTING amp REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM MACHINE LOADED Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 20 volts 5 ms This is the typical DC voltage wave form generated from a properly oper ating machine Note that each verti cal division represents 20 volts and that each horizontal division repre sents 5 milliseconds in time The machine was loaded with a resis tance grid bank The meter reads 500 amps at 40VDC Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal R3R 500 machine O o Fle 5 5 0 PEN 1 SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div pse e Internal Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 37 37 TROUBLESHOOTING amp REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC CH1 A Return to Section TOC Return to Master TOC 2 volts 5 ms This is the typical SCR gate pulse voltage waveform The machine was in an open circuit condition no load and operating properl
32. TOC Return to Master TOC EIE 515 8 TRANSFORMER gle SECONDARY cle LEADS 5 5 8 Read the meter 11 Test with an AC voltmeter for approximate ly across each of the three main secondary start leads located at the SCR Diode Rectifier Bridge Remove the a If proper voltage is present for all three phases proper main input supply volt age is being supplied red insulating paint to achieve good b If proper voltage is not present in any tact if necessary The transformer voltages 515 or all of the three phases check input will vary with the input line voltages See 5 9 fuses and leads Figure 8 See the Wiring Diagram p c 9 Test with an AC voltmeter for proper main a one or more of the above voltage input supply voltage from the output side of tests are incorrect check for loose or 55 the input contactor CR1 See the Wiring faulty connections and Figure F7 Diagram anc Figure Ez b If the connections are good then the a to T2 main transformer may be faulty Re b T2to T3 place the main transformer T1 to T3 10 Read the meter a If the proper voltage is present for all three phases the input contactor is working properly b Ifthe proper voltage is not present for any or all of the three phases the input contactor may be faulty See appropri ate Input Contactor Test Return to Section TOC Return t
33. 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 seront effectu s par un lectricien qualifi debrancher l interrupteur la boite de fusibles place IDEALARC R3R LINCOLN MASTER TABLE OF CONTENTS FOR ALL SECTIONS RETURN TO MAIN INDEX Page Safety i iv Section Technical Specific atlODS A 2 5atety Precattloris x eio iie A 5 Select Suitable Location Stacking Tilting Lifting A 5 Input Connections 6 8 Output Connections Stick TIG Air Carbon Arc A 9 Section B odloty INSIUCHONS M 2 General Description 3 Controls 4 6 Section Maintenance RR Section D 5 0 2 Routine and Periodic
34. connected to the input con 218 case sides and lower the front control tactor CR1 coil located on the input side of the contactor See Figure 5 E 3 Locate the control transformer T2 on the b Lead X2 is spliced into lead 231 See left side of the input box facing the back the Wiring Diagram Lead 231 is of the machine See Figure F 5 connected to the power switch S1 Tilt the front panel forward to access the power switch and Lead 231 con nection See Figure F 6 4 Locate the control transformer primary leads H2 etc See the Wiring Diagram NOTE Unused leads should be taped a Inspect for broken or incorrect con nections Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 18 F 18 TROUBLESHOOTING amp REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued MACHINE FRONT CONTROL PANEL LEAD 231 CONNECTION METER PROBE RIGHT SIDE VIEW 6 Test for 115VAC between leads X1 and 231 NOTE If the main AC input supply voltage varies the control transformer voltage will vary by the same percentage a Connect one end of an insulated alliga tor clip to the X1 connection at the input contactor CR1 coi
35. electrode polarity of the output terminals between and DC 9 DC AMMETER optional Displays output cur rent when welding 10 DC VOLTMETER optional Displays output voltage 11 THERMAL PROTECTION INDICATOR LIGHT This amber light indicates that either of the two protective thermostats has opened Output power is removed but input power is still being applied to the machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 gt 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC B 6 B 6 OPERATION WELDING OPERATION OPERATING STEPS LOCAL CONTROL The following procedures are for using the Idealarc the local R3R control mode of operation For remote control of the machine see the REMOTE CONTROL section Before operating the machine make sure you have all materials needed to complete the job Be sure you are familiar with and have taken all possible safety pre cautions before starting work It is important that you follow these operating steps each time you use the machine 1 Turn on the main AC input power to the machine 2 Set the ELECTRO
36. faulty The input contactor chatters 1 Make certain the three phase 1 Perform input voltage matches the rat ing plate and the reconnect panel Return to Section TOC Return to Master TOC The machine has high welding out If the remote control is being Check the Output Control put and no control used set the output control Switch SW2 and the Dial switch SW2 to the Machine or Selector Switch SW3 and Local position and control the associated wiring See the weld output with the machine Wiring Diagram ARI Check the feedback leads prosent 1a ss sol IE 205 206 204 and 225 for remote control unit and associ loose or faulty connections ated cable leads If the Pocket Amptrol option is being used 3 Perform the SCR Diode the Pocket Amptrol circuit may Rectifier Bridge Test be faulty If the Pocket Amptrol is not functioning properly perform the Pocket Amptrol Circuit 7 2 The control board may be O O HE 9 9 5 c faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section
37. located on the floor of the input box is provided for this purpose See the U S National Electrical Code for details on proper ground ing methods INPUT SUPPLY CONNECTIONS Input power is connected to the three line terminals on the input contactor See Figure A 2 Be sure the volt age phase and frequency of the input power is as specified on the rating plate IDEALARC LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC 7 INSTALLATION FIGURE A 2 INPUT POWER SUPPLY CONNECTIONS 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL 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 INPUT WIRE AND FUSE SIZE Fuse the input circuit with super lag fuses or delay type circuit breakers as recommended on the Technical Specifications page Choose an input and grounding wire size according to local or national codes also see the appropriate Specifications page Using fuses or circuit breakers smaller than recommended may result in nuisan
38. machines on top of lighter machines For example do not place an R3R 500 on top of 400 or R3R 400 on top of an 300 IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 3 Return to Section TOC Return to Master TOC 2 INSTALLATION INPUT CONNECTIONS ELECTRIC SHOCK can kill e Have a qualified electrician install and service this equip ment Turn 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 ground Always wear dry insulating gloves Be sure the voltage phase and frequency of the input power is as specified on the rating plate located on the case front control panel See Figure A 1 Also see appropriate Technical Specifications page for input and ground wire requirements FIGURE A 1 RATING PLATE LOCATION 1 RATING PLATE Input supply line ground lead entry is through a hole located at the top of the case rear panel A removable door covers the input connection box which contains the input contactor CR1 and reconnect panel assem bly for multiple voltage machines GROUND CONNECTION The welder frame must be grounded A stud marked with the symbol
39. not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn Tighten first cap screw 1 8 turn Tighten second cap screw 1 8 turn STOP A N Assembly now has the proper clamping force 9 Perform the Active SCR Test IDEALARC R3R LINCOLN F 52 F 52 TROUBLESHOOTING amp REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS Return to Section TOC Return to Master TOC WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD Return to Section TOC Return to Master TOC DESCRIPTION The following procedure will ai
40. o 2 2 os pem ARR dco LI I MEN MC D MC S CM CE dels Pt B _ 1 Lid 3 1 1 AMPHENOL CONTROL l l TERMINAL biii 1 5 CONTROL bog TRANSFORMER e ES SWITCH OUTPUT 5 TERMINAL THERMOSTATS L 5 2 1 5 R SWITCH 2 N A INPUT MAIN SCR DIODE SHUNT POSITIVE CONTACTOR TRANSFORMER HYBRID BRIDGE TERMINAL 5 FIGURE 1 IDEALARC R3R BLOCK LOGIC DIAGRAM 5 IDEALARC LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 515 PEN 2 818 tt 5 2 1 Return to Section TOC Return to Master TOC E 2 E 2 THEORY OF OPERATION FIGURE E 2 INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER POGRET OPTIONAL TRANSFORMER AMPTROL PC BOARD AMPHENOL CONTROL 1 1 1 1 1 1 STRIP 1 TRANSFORMER THERMOSTATS domzzoomz MAIN INPUT CONTACTOR TRANSFORMER GENERAL DESCRIPTION The Idealarc welder is a three phase transformer rectifier type constant current power source designed for DC manual welding and air carbon arc cutting Its power system is SCR controlled with solid state elec tronic circuitry Minimum
41. of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points Components terminal strips etc can be found on the referenced elec trical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram A CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC R3R LINCOLN F 2 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 3 F 3 TROUBLESHOOTING amp REPAIR PC BOARD TROUBLESHOOTING PROCEDURES WARNING ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the machine OFF before working on equipment Do not touch electrically hot parts Sometimes machine failures appear to be due to PC board failures These problems can sometimes be traced to poor electrical connections To avoid prob lems 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 m
42. phase input lines are connected cor rectly to the R3R machine 2 Check the Input Power Switch 51 and associated leads See the Wiring Diagram Perform the Input Contactor CAUTION If for any reason you do not understand the test procedures or unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 E Return to Section TOC Return to Master TOC o 7 2 TROUBLESHOOTING 4 REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The output terminals are always electrically hot POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS This is a normal condition The open circuit voltage should be approximately 67VDC The open circuit voltage may vary with the input line voltage TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION The machine welds but reduces to a low output under load and remains there until the load is removed and the arc re started The machine shuts off even when not under load or makes excessive noise li
43. supply power to the machine Locate and get access to the input contac tor in the input box See Figure 25 Disconnect the main input supply power leads L1 L2 and L3 to the input contactor Remove the control transformer primary leads H1 H2 or dependent on input volt age from L1 and L3 terminals on the input side of the contactor Disconnect the output leads T1 T2 and T3 from the input contactor Identify and label the leads connected to the input contactor coil Diagram See the Wiring Disconnect the leads from the input contac tor coil leads X1 232 and 233 See the Wiring Diagram Remove the three self tapping mounting screws using a 5 16 socket wrench See Figure F 25 Remove the input contactor 9 Insert the replacement input contactor and IDEALARC R3R LINCOLN install it following the procedures in reverse order NOTE Be sure to reconnect all leads cor rectly F 41 F 41 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to S
44. 0 519400 3321 alz R61 4231 15 68 5W R54 519400 2211 R55 19400 3323 856 857 858 862 863 864 92 93 94 9 4231 11 100 1 2W 868 869 870 871 872 873 6 519400 2671 R90 0812 41 10K 1 2W SCR1 SCR2 8CR8 3 _ 515161 19 TP1 TP2 TP8 3 3640 12 38J 1 2 2 515128 9 X3 1 515128 4 R92 R93 R94 CAPACITORS MFD VOLTS RESISTORS OHMS 1 4 UNLESS OTHERWISE SPECIFIED INDUCTANCE HENRYS E p 212 218 JE 2 NOTE Lincoln Electric assumes responsibility for resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result ELECTRIC in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine R3R G 9 ELECTRICAL DIAGRAMS G 9 R3R 400 Control PC Board
45. 0 64 72 0 Welding Output Terminals 50 61 69VDC O10 515 0 gt 8 1 WELDING OUTPUT LOAD TEST Output Control Settings Volts Dial Selector at A 20VDC Maximum Minimum Dial Selector at 44 to 49 VDC Maximum Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 64 5 ao F 5 lt 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 64 201 uonoes uumeg DOL uonoes uumeg 201 uonoes DOL uonoes Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 gt 1 Return to Section TOC Return to Master TOC ELECTRICAL DIAGRAMS TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Wiring 0 gues 6 3 Wiring Diagram R3R 400 Code 9537 G 4 Wiring Diagram 400 Code 9874 500 G 5 Pocket Amptrol G 6 Snubber Board Schematic amp Layout G 7 300 Control coi teme
46. 2 29 29 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 16 CONTROL BOARD PLUG P1 AND P3 LOCATIONS FIGURE F 17 CONTROL BOARD G1575 LEAD LOCATIONS R3R CONTROL 52205 Plug P4 Removed FIGURE F 18 SNUBBER BOARD PLUG P5 LOCATION Plug P5 M15370 SNUBBER TEST PROCEDURE 1 Disconnect the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Remove the screws holding the front panel and lower the panel Disconnect the welding cables from the welding output terminals Locate and remove molex plug from 6 trol board G2206 See Figure F 16 If the machine has control board G1575 dis connect the individual gate leads G1 G2 and G3 and also lead 204 See Figure F 17 IDEALARC R3R LINCOLN G2 R3R CONTROL Giles FIGURE 2 19 RESISTOR LOCATION RESISTOR R3 5 Locate and remove molex plug P5 from snubber board M15370 See Figure F 18 If the machine has snubber board M14215 it will be necessary to label and disconnect lead 204 from the output shunt Be sure to disconnect the 204 lead that runs between the snubber board and the out put shunt Locate and remove lead 204 from resistor R3 40 ohms 50 Watts See Figure F 19
47. 4 BOTTOM E IRON GLASTIC STIFFENERS 2 3 REMOVAL OF CHOKE AND TOP IRON ASSEMBLY 1 Remove the two left and right glastic stiffen 6 Using hoist carefully lift the choke and top p ers connecting the negative rectifier plate iron assembly out and clear of the trans 8 choke assembly to the main transformer former coils Aru Dolls ee Figure NOTE The coils may be stuck to the top iron E 2 Remove the top choke lead from the polarity and may require some careful prying to selector switch or the negative output termi dislodge them Depending upon which coils are to be replaced it may be advantageous to remove some of the 3 Remove the bottom choke lead from the neg stuck coils with the top iron ative rectifier plate 7 The leads from the coils that are to be removed and or replaced must be discon 5 Using the 9 16 deep well socket wrench nected See the Wiring Diagram remove the four thru bolts that clamp the top E iron and choke assembly to the bottom E iron NOTE for easier reassembly clean the threads 4 Label and cut the choke thermostat leads When aluminum leads are re connected apply a thin layer of Dow Corning 340 Heat Sink Compound to mating surfaces Return to Section TOC Return to Master TOC IDEALARC R3R LINCO
48. 43 556 2 lt 5 4 2200220 9531 ozrgiz6o959900 Oo2oOorczZiro roo amp amp eo Se 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 901 J91Se N 001 uonoes 0 001 uonoes 0 uunjeg 001 uonoes 0 001 uonoes 0 0 4 5 ao F 5 lt 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 0 4 201 uonoes uumeg DOL uonoes uumeg 201 uonoes DOL uonoes Section E 1 Section E 1 TABLE OF CONTENTS O THEORY OF OPERATION SECTION d Theory of Operation ici Section E T 2 5 Input Line Voltage Contactor and Main E 2 Output Mode and Control Rectification and Feedback E 3 Optional Polarity Switch and Amptrol Circuits 4 Protective Devices and Save d 5 6 O
49. 50 18 19 20 3 111577 62 1 200 021 022 023 3 513490 102 047 100 C81 111577 57 0 17400 D1 D2 D3 3 112199 2 N4007 D4 D5 D6 D7 D8 D9 D10 D11 D12 D13 D14 D6 D27 Dee 0029080032015 30 1121994 N4004 Q gt QO 9 9 e 9 D31 D32 D33 3 2199 4 IN4005 n E DZ1 1 2702 23 1N5352B Fls DZ2 1 2702 33 N5347B olo z 5 023 1 12702 9 N5234B ola 5 J 024 1 2702 40 N4735 ale cmp DZ5 DZ6 DZ7 DZ8 4 2702 29 1N4744A alt P 079 1 2702 8 1 5240 918 508 g 9 815000 1828 8 15 OCI2 0CI3 2 515000 5 01 02 2 2704 69 254403 8 spy gt 5 5 S QU1 QU2 QU3 3 2707 4 B x ac 2 3 3 2300 73 250 20W amp 84 85 86 87 88 89 6 114648 12 1500 5W 5 R10 R29 R52 3 0812 67 100K 1 2W R11 R48 2 19400 1503 8 812 815 821 827 4 519400 2672 5 n R13 R14 R32 R35 R37 R39 R80 R81 R82 9 19400 1003 ST R16 1 0812 62 500 1 2W tu R17 R18 R47 R89 4 19400 6813 19 20 22 98 99 100 R101 R102 R103 19400 1004 R23 R65 R66 R67 4 110812 39 50K 1 2W lE R24 1 519400 6811 pe a eu R25 R26 R41 R77 R78 R79 6 19400 4751 E amt 25 515 S JU R28 R45 R74 R75 R76 5 8194002213 el R30 R31 R91 3 T14230 23 5 0 MEG 11 _ 833 1 19400 5622 2 5 als 834 895 896 807 4
50. 60V 44A RATED OUTPUT Duty Cycle Volts at Rated Amps 10096 44 6096 40 3596 35 OUTPUT Current Range Maximum Open Circuit Voltage 75 to 625 Amps 67 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES 60 DUTY CYCLE Input Wire Size Ground Wire Size Input Voltage Fuse Input Ampere Type 75 C Type 75 C Frequency Super Lag Rating on Copper Wire in Copper Ground or Breaker Size Nameplate Conduit Wire in Conduit Volts Hz AWG IEC Sizes AWG IEC Sizes 230 60 4 25 mm 460 60 8 10 mm PHYSICAL DIMENSIONS Height Depth Weight 27 50 in 33 10 in 446 Ibs 700 mm 840 mm 202 kg IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 lt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC A 5 A 5 INSTALLATION Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves Only qualified personnel should install use or ser vice this equipment SELECT SUITABLE LOCATION Place the Idealarc in dry location where clean cooling air can flow freely in through the front louvers and out through the rear
51. DE POLARITY switch to the appropriate position optional if equipped 3 Set the OUTPUT CONTROL switch to 4 Set the ARC FORCE CONTROL to midrange 5 6 for CC stick or TIG welding Adjust for best char acteristics as necessary 5 Set the ON OFF POWER toggle switch to the ON position 1 The white power source pilot light glows The fan starts 6 Set the CURRENT RANGE SELECTOR switch to the appropriate position for higher range B for lower range 7 Set OUTPUT CONTROL potentiometer to desired current 8 Make the weld REMOTE CONTROL The toggle switch on the control panel labeled Output Control Remote gives you the option of controlling the machine output from a remote location In the Remote position a remote control device such as a K857 must be connected to the Idealarc R3R Refer to the Accessories section for available remote control information POCKET AMPTROL Optional The pocket amptrol option provides a remote current control for the R3R welders This wireless control requires no control cable connection to the welder Use it as follows a On the R3R 400 and 500 the welder CURRENT CONTROL switch must be in the Remote posi tion and the CURRENT RANGE SELECTOR switch in the B range The 300 does not have CURRENT RANGE SELECTOR switch With the CURRENT CONTROL switch in the Remote tion the OUTPUT CONTROL potentiometer on the we
52. GE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will determine if the correct voltages are being applied to the primary windings of the Main Transformer T1 and induced on the secondary winding auxiliary windings and phase angle windings MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver IDEALARC Wiring Diagrams See the Electrical Diagrams section of this manual This procedure takes approximately 25 minutes to perform IDEALARC R3R LINCOLN F 19 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC 7 2 20 20 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 V
53. H 901 J91Se N 0 901 01 DOL uonoes uumeg DOL uonoes uumeg DOL DOL G 8 ELECTRICAL DIAGRAMS G 8 R3R 300 Control PC Board e o 9 REQ D PART No IDENTIFICATION o C1 13490 8 50 25 62 030 2 13490 35 50 15 OR 16 C8 513490 4 022 200 4 09 2 516668 3 100pF 100 cle 5 010 027 028 029 5 16668 5 022 50 5 5 C6 813490 62 00337200 alz 7 012 14 015 024 025 026 7 11577 98 02 600 813490 73 20 50 018 019 020 3 T11577 62 1200 C21 022 023 3 513490 102 047 100 C3 T11577 57 0 1 400 01 02 03 712199 2 4007 6 Os o 2 gt m D24 D25 D26 D27 28 029 D30 034 035 29 12199 1 4004 036 e 031 032 033 3 T12199 4 N4005 2 5
54. L CIRCUIT TEST continued FIGURE 21 TRANSFORMER AND LEADS POCKET AMPTROL TEST PROCEDURE 1 Remove input power to the R3R machine 2 Using the ohmmeter check the resistance from one probe to the other probe at the Pocket Amptrol Normal resistance is 700 ohms when the dial is at the 1 position When the dial is rotated toward the 10 posi tion the resistance from probe to probe should decrease to approximately 200 ohms If the measured resistance is not correct the Pocket Amptrol may be faulty 3 Using the 5 16 nut driver lower the front panel and locate the Pocket Amptrol trans former T3 inside the control box compart ment See Figure F 21 NOTE If the machine is equipped with a polari ty switch the switch handle will have to be removed using a 1 8 Allen type wrench WARNING Electric Shock can kill With the input power on Y there are high voltages inside the machine not reach the machine or touch any internal part of the machine while the power is on 4 T IDEALARC R3R LINCOLN TRANSFORMER T3 POCKET AMTROL Apply the correct input power to the machine Check the primary voltage at leads 201A to 203A See Figure 21 Normal voltage is approximately 120VAC If the primary volt age is missing or low check the leads and associated connections Check the T3 secondary voltages at plug P7 located on the Pock
55. LN P 57 57 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 35 EPOXY MIX APPLICATION AREAS Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC REASSEMBLY OF TRANSFORMER COILS NOTE The following procedure describes a complete replacement of all primary and sec ondary transformer coils Adapt the procedure for the specific coils you may be replacing 1 Apply a coating of Lincoln Electric E2547 Epoxy Mix along both sides of the bottom iron lamination assembly in the areas where the coil sides will be mounted Coat the areas no closer than 38 inches from the top edge of the iron See Figure F 35 arrows Be sure that none of the epoxy drips onto the top of the iron assembly where it will meet the top assembly O10 515 0 gt 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN F 58 F 58 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC FIGURE F 36 COIL LEAD PLACEMENT MACHINE FRONT SECONDARY COIL LEADS 3 Install the bottom primary coils one on each of the three legs of the bot
56. Measure the resistance from the anode to the cathode of SCR 1 using an analog volt ohmmeter multimeter set at R x 1000 scale See Figure F 15 a Reverse the meter leads and measure the resistance from the cathode to the anode of SCR 1 See Figure 15 b low resistance is measured in either meter polarity SCR1 is faulty Replace SCR 1 Test the resistance of SCR 2 and SCR 3 using the same procedure described in Step 8 Measure the resistance of diode D1 from anode to cathode probe using an analog ohmmeter set at R x 1000 scale The resistance should be low See Figure 15 a Reverse the meter leads and measure the resistance from cathode to anode probe of diode D1 The resistance should be high See Figure 15 b If alow resistance is measured both meter polarities diode D1 is shorted Replace diode D1 c lfahigh resistance is measured in both meter polarities diode D1 is open Replace diode D1 11 Test diodes 02 D3 and 04 for proper oper ation using the same procedure described in Step 10 12 Reconnect all leads and molex plugs Resolder lead 204 at resistor R3 13 If this test did not identify the problem or to further test the SCRs go to the Active Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 28 28 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST WARNING Service and repai
57. N OUTPUT CONNECTIONS STICK TIG AIR CARBON ARC CUTTING The output welding cables are connected to the out NOTE If the welder comes equipped with the polarity put terminals marked and See Table for Switch option the output terminals are labeled recommended cable sizes for the combined lengths of electrode and to work electrode and work cables The output terminals are located at the lower right and lower left corners of the A WARNING front panel Strain relief for the cables is provided by routing them through the rectangular holes in the base output terminals are energized at all times before connecting them to the output terminals See Figure Return to Section TOC Return to Master TOC FIGURE A 4 OUTPUT TERMINAL CONNECTIONS Return to Section TOC Return to Master TOC 1 NEGATIVE WELDING CABLE CONNECTION 2 POSITIVE WELDING CABLE CONNECTION 3 CABLE STRAIN RELIEF HOLES TABLE A 1 CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE AND WORK CABLES p Up to 100 ft 100 150 ft 150 200 ft 200 250 ft Machine Size 30 m 30 46 m 46 61 m 67 76 m 300 Amp 1 0 1 0 2 0 3 0 60 Duty 54 mm 54 mm 68 mm 86 mm Cycle Fle 515 0 gt 2 1 400 2 0 2 0 3 0 4 0 60 68 68 86 108 mm 500 2 0 3 0 3 0 4 0 60 68 86 86
58. NM NM TERMINAL Em 219 5 Es 04 AMPTROL 2 218 SENSING PSI SHUNT 5 5 POCKET AMPTROL 2465 146 TRANSFORMER T3 CONTROL SCR DIODE omm P C RECTIFIER HOM BOARD BOARD BRIDGE 5J6 4 6 3J6 5J1 77 MACHINE 515 REMOTE 519 SWITCH 218 cle OUTPUT 5 5 TERMINAL tio cc IDEALARC R3R LINCOLN 5 F 35 F 35 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING NO LOAD Return to Section TOC Return to Master TOC HHH 0 volts Return to Section TOC Return to Master TOC 50 volts 5 This is the typical DC open circuit voltage waveform generated from a properly operating machine Note that each vertical division represents 50 volts and that each horizontal divi sion represents 5 milliseconds in time Note Scope probes connected at machine output terminals probe to positive terminal probe to neg ative terminal R3R 500 machine O o Fle 5 5 0 PEN 1 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling aei DC Trigger Internal Return to Section TOC Return to Master TOC IDEALARC
59. NNECTIONS NOTE MACHINES ARE SHIPPED FROM FACTORY CONNECTED FOR OVER 300 VOLTS CONNECTION FOR HIGHEST RATING PLATE VOLTAGE 50 OR 60 HZ 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX 2 DISCONNECT AND INSULATE THE H2 LEAD TERMINAL WITH TAPE TO PROVIDE AT LEAST 600 VOLT INSULATION 3 CONNECT L1 L2 amp L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN 4 CONNECT TERMINAL MARKED TO GROUND PER LOCAL AND NATIONAL ELECTRIC ODES 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS DOUBLE UP THE LINKS IN TWO OF THE POSITIONS TO SAVE THEM FOR FUTURE USE SECURE THE REMAINING HEX NUTS IN PLACE CONNECTION FOR LOWEST RATING PLATE VOLTAGE 50 OR 60 HZ LINK 1 TURN OFF THE INPUT POWER USING THE DISCONNECT SWITCH AT THE FUSE BOX o 9 2 DISCONNECT AND INSULATE THE H3 LEAD TERMINAL WITH TO PROVIDE LINES 5 LEAST 600 VOLT INSULATION INPUT CONTACTO 3 CONNECT L1 12 amp L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS ou TO THE INPUT SIDE OF THE CONTACTOR SHOWN H1 4 CONNECT TERMINAL GROUND PER LOCAL AND NATIONAL ELECTRIC GND H2 H3 e CODES PILOT 5 MOUNT THE LINKS IN THE POSITIONS SHOWN WITH THE PROVIDED HEX NUTS TRANSF THE LINCOLN ELECTRIC CO CLEVELAND OHIO U S A 15009 IDEALARC R3R LINCOLN INSTALLATIO
60. OC IDEALARC R3R LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC 7 2 51 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued CLAMPING PROCEDURE FOR 1 4 28 CAP SCREWS NOTE This procedure can only be used with 1 4 28 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do not over tighten cap screws The leaf spring will apply the required clamping force to the SCR 1 Do not turn the nuts While holding the nuts stationary turn the cap screws only with the following procedure Tighten first cap screw 1 4 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 2 turn Tighten first cap screw 1 2 turn Tighten second cap screw 1 4 turn STOP Assembly now has the proper clamping force 9 Perform the Active SCR Test AFTER REPLACING THE SCRs Follow the steps in the SCR Diode Rectifier Removal and Replacement procedure to reassemble the machine CLAMPING PROCEDURE FOR 1 4 20 CAP SCREWS NOTE This procedure can only be used with 1 4 20 cap screws Do not use cap screws with any other type thread or new SCR will be damaged Do
61. OLTAGE TEST continued FIGURE F 7 INPUT CONTACTOR RECONNECT PANEL AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS INPUT SUPPLY INPUT RECONNECT CABLE ENTRY CONTACTOR PANEL OPENING CR1 ASSEMBLY MAIN TRANSFORMER Ss LEADS d L J L JD 1 JON 2 t 4 Ak JA J FRONT VIEW SIDE VIEW TEST PROCEDURE 1 Set the ON OFF power switch to OFF 5 Connect main input supply power to the machine 2 Disconnect main input supply power from the machine Set ON OFF power switch to ON 3 With the 5 16 nut driver remote the case a Make sure the input contactor CR1 top and sides and the reconnect panel energizes and the fan runs cover 7 Test with an AC voltmeter for proper main 4 Inspect the input contactor reconnect panel and primary leads to the main trans former for loose or faulty connections See Figure F 7 a Confirm that the reconnect panel is connected properly for the three phase main input supply power supplied to the machine See the reconnect panel connection diagram located on the inside of the input box assembly access door input supply voltage to the line side of the input contactor CR1 the Wiring Diagram a L1 to L2 b L2 to L3 L1 to L3 IDEALARC R3R LINCOLN 21 21 TROUBLESHOOTING 4 REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 8 MAIN SECONDARY LEAD TEST POINTS Return to Section
62. P a amp Assembly now has the proper clamping force 7 Perform the Active SCR Test IDEALARC R3R LINCOLN 5 50 F 50 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 31 HOUSING AND PRESSURE PAD FOR 5 8 WIDE LEAF SPRING STEEL PRESSURE PAD Return to Section TOC Return to Master TOC HOUSING PROCEDURE FOR THE FIGURE F 32 CLAMP ASSEMBLY 5 8 INCH WIDE SPRING 1 Place a piece of sleeving around each cap Screw Return to Section TOC Return to Master TOC 2 Insert cap screws through the leaf spring The leaf spring is flat so the orientation of the leaf spring does not matter 3 Place the steel pressure pad in the housing with the 1 8 inch wide standoff facing up See Figure 31 4 Insert cap screws and leaf spring into plastic housing being sure that the steel pressure pad remains in position Pressing on the cap screw heads should produce a rocking action of the spring in its housing HEAT SINK 5 Insert the clamp assembly through the heat sinks Install nuts Tighten the clamp nuts equally on the cap screws until finger tight Be sure that the leaf spring is not cocked in the housing See Figure 2 Heat sinks may not be exactly as pictured Fle 5 5 0 PEN 2 1 6 Reinspect the SCR for proper seating HOUSING LEAF SPRING CAP SCREW Return to Section TOC Return to Master T
63. Return to Master Return to Master TOC O o 9 5 Return to Master View Safety Info View Safety Info 9 gt o 2 gt SERVICE MANUAL View Safety Info IDEALARC SVM139 A June 1998 R3R 3UL 400 and 500 For use with machine code numbers 9534 9537 9874 and 9884 Safety Depends on You Lincoln arc welding and cutting equipment 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 READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful World s Leader Welding and Cutting Products ELECTRIC Premier Manufacturer of Industrial Motors Sales and Service through subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can cer birth defects and other reproductive harm The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other repro
64. Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 0 PEN i 1 Return to Section TOC Return to Master TOC Return to Master TOC F 30 10 11 12 13 14 30 TROUBLESHOOTING amp REPAIR ACTIVE SCR TEST continued FIGURE F 20 SCR TESTER CIRCUIT AND SCR CONNECTIONS swi R2 6 VOLT LANTERN BATTERY Remove the red insulating paint from the heat sink test points See Figure F 20 NOTE Do not disassemble the heat sinks Construct the circuit shown in Figure F 20 One 6 volt lantern battery can be used Set voltmeter scale low at approximately 0 5 volts or 0 10 volts Test the voltage level of the battery Short leads A and C Close switch SW 1 Battery voltage should be 4 5 volts or higher If lower replace the battery Connect the tester to the SCR 1 as shown in Figure F 20 a Connect tester lead A to the anode b Connect tester lead C to the cathode c Connect tester lead G to the gate NOTE Gate leads can be accessed at molex plug P4 Control board G2206 or terminals Control board G1575 See Figures 16 17 Close switch SW 1 NOTE Switch SW 2 should be open Read meter for zero voltage If the voltage reading is higher than zero the SCR is shorted Close or keep closed switch SW 1 Close switch SW 2 for 2 seconds Release and read meter Lew
65. Section F 1 Section F 1 TABLE OF CONTENTS TROUBLESHOOTING 4 REPAIR SECTION 8 gt Troubleshooting amp Repair Section Section How to Use Troubleshooting F 2 5 PC Board Troubleshooting Procedures F 3 Troubleshooting F 4 F 9 Test Procedures Input Contactor Test Equipped with AC F 10 Input Contactor Test 300 Equipped with DC F 13 Control Transformer T2 Voltage F 16 Main Transformer T1 Voltage F 19 Static SCR Diode Rectifier Bridge F 24 Active 2 28 Arriptrol Circuit enini F 31 5 Oscilloscope rtt F 35 9 Normal Open Circuit Voltage Waveform Maximum Output No F 35 Typical Output Voltage Waveform Machine F 36 5 Typical SCR Gate Voltage Waveform Maximum Output F 37 Abnormal Open Circuit Voltage Waveform One Output SCR Not Functioning F 38 2 9 Replacement Procedures F 39 Input Contactor
66. TOC Return to Master TOC IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 6 F 6 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS The machine has minimum or very low welding output and no con trol POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Make certain the three phase input voltage is correct and matches the rating plate and the reconnect panel Make certain the Dial Control Switch SW3 is the correct position Not present on R3R 300 If the remote control is being used set the Output Control Switch SW2 to the Machine or Local position and control the weld output with the machine Output Control R1 the problem is resolved check the remote control unit and associ ated cable leads If the Pocket Amptrol option is being used the Pocket Amptrol circuit may be faulty Make sure the remote control leads 75 76 77 are not grounded or shorted to the positive or negative welding output RECOMMENDED COURSE OF ACTION 1 2 3 4 5 Check the Output Control R1 and associated wiring See the Wiring Diagram Check the Output Control Switch S2 and associated wiri
67. Y HOLO3NNOO 1081400 10719 08 08 u388NS st 08708 O d 13004 1 01190 3319 WNOLLdO AINO 1N3S38d 50731 393 7933 938 ex ELECTRICAL DIAGRAMS 1 09 H NOLLO3NNOO 1 1 0 ON 0 7 1VISONH3HL 8 0 0935 1vISONB3HL 33089 s amp 0 dN3L idi YOLOW 3 390188 93134933 09908 30 3016 IN3NOdWOO 39 3103 fic to your code is pasted inside one of the enclosure panels of your mach o o NO Mon S 3LIH u3g 9801002 LNdNI 2 19310 INSISNVHL am H3INHOJSNVHL NOlLdO 1 13 004 45 1 1041400 g 390148 HOLOVLNOO 1 em 390149 4911934 30010 ANY 898 10 1908 E NO ZH 09 HOLIMS ALIHYTOd YMS D HOLIMS 80103135 Wid 6 6 HOLIMS ZMS HOLIMS 30191634 ONISN3S 4 1320204
68. aded areas of Block Logic Diagram are the subject of discussion IDEALARC R3R LINCOLN 5 3 E 3 THEORY OF OPERATION FIGURE E 3 OUTPUT RECTIFICATION CONTROL AND FEEDBACK e 515 PEN 2 Sg qwe c m D M rj aoe I 4 AMPHENOLC TERMINAL STRIP ARC FORCE CONTROL REMOTE Q TRANSFORMER FEEDBACK 2 CONTROL BOARD NEGATIVE MOTOR OUTPUT TERMINAL 1 1 SELECTOR NI CONTROL SWITCH i SWITCH 1 1 OPTIONAL Return to Section TOC Return to Master TOC B PI 5 B 1 N l N K 1 l l l I INPUT MAIN SCR DIODE SHUNT HYBRID BRIDGE TERMINAL OUTPUT RECTIFICATION CONTROL AND FEEDBACK The three phase AC output from the main transformer secondary is rectified and controlled 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 control board The control board compares the commands from Arc Force Control the Dial Selector switch and the Output Control or remote control with the feedback informa tion and sends the appropriate gate firing sig
69. 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 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 1 e some cases it may be necessary to remove safety 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 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running 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 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot a ELECTRIC AND MAGNETIC FIELDS may dangerous 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician b
70. ant que possible l installation et l entretien du poste 3 Avant de faires des travaux l interieur de poste la 4 Garder tous les couvercles et dispostifis de s ret leur 7 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 8 S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de la faire Si on place la masse 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 levage c bles de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent 9 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 fum es toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op erations 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 roxique ou autres produits irritants PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFOR MATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement
71. aster R3R CONTROL G2206 FIGURE F 10 CONTROL BOARD 61575 TEST POINTS CONTROL 201 5 Hh oa 9 202 218 203 2 2 204 TABLE F 1 PHASE ANGLE WINDING VOLTAGES From Lead To Lead Expected VAC 201 204 66 VAC 202 204 66 VAC 203 204 66 VAC Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 24 24 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if an SCR or diode is shorted or leaky See the Machine Waveform Section of this manual for normal and abnormal output waveforms Return to Section TOC Return to Master TOC MATERIALS NEEDED Analog Volt
72. aster TOC 7 2 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Major physical or electrical dam age is evident when the sheet metal cover s are removed POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your local authorized Lincoln Electric Field Service Facility for technical assistance TROUBLESHOOTING GUIDE RECOMMENDED COURSE OF ACTION 1 Contact the Lincoln Electric Service Department 216 383 2531 or 1 800 833 9353 WELD Machine is dead no output no fan no pilot light Make sure that the input power switch is in the ON position Check the three phase input voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input lines Check the input power switch S1 for proper operation See the Wiring Diagram Check the leads associated with the power switch S1 and the control transformer T2 for loose or faulty connections See the Wiring Diagram 3 Perform the The machine is dead not output no fan the pilot light is on The amber temperature light is NOT on Check the three phase voltage at the machine Input voltage must match the rating plate and the reconnect panel Check for blown or missing fuses in the input li
73. at distances up to 200 ft 61m from the power source Two lengths are available 22 5ft 6 9m or 45ft 13 7m 22 5 ft K937 22 5 45 ft K937 45 IDEALARC R3R LINCOLN amp Section 0 1 Section 0 1 TABLE OF CONTENTS MAINTENANCE SECTION gt EE Section D Safety Precautions at D 2 5 Routine and Periodic 0 2 General Component 0 3 Return to Master o 0 2 Return to Master TOC IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC D 2 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Only qualified personnel should perform this mainte nance Turn 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 materials are around the machine or in the welding or cutting area 2 Remove any debris dust dirt or materials that could block cooling air flow to the machine 3 Inspect the electrode cables for any slits or punc tures in the cable jacket A
74. cal 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 malfunc tions 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 symp toms that the machine may exhibit Find the list ing that best describes the symptom that the machine is exhibiting Symptoms are grouped into two main categories Output Problems and Welding Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the sub ject component is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end
75. ce shut offs from welder inrush currents even if you are not welding at high currents IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC O o Fle 5 5 0 PEN 1 Return to Section TOC Return to Master TOC Return to Master TOC A 8 A 8 INSTALLATION RECONNECT PROCEDURE Multiple input voltage welders are shipped connected for the highest voltage listed on the machine s rating plate Before installing the welder be sure the recon nect panel is connected for the proper voltage Failure to follow these instructions can cause immedi ate failure of components in the welder To reconnect a multiple voltage machine to a different voltage remove input power Follow the input con nection diagram located on the inside access panel cover appropriate for your machine s input voltage These same connection diagrams are shown below For 208 208 230 amp 230 460 volts AC see Figure A 3 FIGURE A 3 INPUT CONNECTION DIAGRAM FOR 208 208 230 and 230 460 VOLTS AC 50 60 HZ HIGH VOLTAGE CAN KILL Do not operate with covers Do not touch electrically live parts remove Disconnect input power before Only qualified persons should install servicing use or service this equipment DUAL VOLTAGE MACHINE INPUT SUPPLY CONNECTION DIAGRAM IMPORTANT CHANGE LINK POSITIONS AND PILOT TRANSFORMER CO
76. cepas G 8 RSR 400 Control PO Board erotico rr titt Em bae x FF HEP G 9 R3R 500 Gontrol PO Board eit nio smi est S G 10 LINCOLN 5 G 1 2 5 ao F 5 lt 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 901 J91Se N 01 2 201 uonoes uumeg DOL uonoes uumeg 201 uonoes DOL uonoes G 3 9 0 5 405 16 8 z 69087 ados EUH V S 1 5 006 345709 91419373 NIOONIT IHL awya vers qo 18 3349Y 01 n 32NVH3101 334930 V 30 SF SI STI9NY TIV 200 SI STVWIO3Q NO 20 SI STVWIO3Q NO 95053 43d 53215 310H NO 5 501251 s anv 09 91815313 1 JHL 104 Q313193dS 1 SNIV 1NOO SIHL Ine 709 918193713 109 13 NOISSIINH3d LNOHLIM OL LON GNNOYS NOILISOd 19207 NI NMOHS HOLIMS 9 SI 198004 WNOILdO N3HM 0351 LON 5031 ASSHL AN
77. ching 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 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c CYLINDER may explode 22384 if damaged 7 Us
78. con the machine tinuity across the contacts Zero ohms or very low resistance is normal See Figure F2 If the resistance is high the input con tactor is faulty Replace the input contactor 5 When the contactor is NOT activated the resistance should be infinite or very high across the contacts If the resistance is low the input contactor is faulty Replace the input contactor 2 Remove the three leads connected to the input contactor coil 233 and 1 232 See Figure 2 for location 3 Using the external 120VAC supply apply 120VAC to the terminals of the input con tactor coil If the contactor does NOT acti vate the input contactor is faulty Replace the input contactor Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN F 13 F 13 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST FOR 300 EQUIPPED WITH DC COIL ON INPUT CONTACTOR WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test proce
79. d 204 from the out put shunt Be sure to disconnect the 204 lead that runs between the snubber board and the output shunt Locate and remove lead 204 from resistor 40 ohms 50 watts See Figure 14 On R3 reassembly resolder this lead Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 26 FIGURE F 14 2 5 lt 7 2 5 5 5 m EH 2 PCENA VS lt z J IS NV M a 2 e LL TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued F 26 901 J91Se N 01 901 01 901 J91Se N 01 901 J91Se N 01 DOL DOL uonoes 901 uonoes DOL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 3 7 2 27 27 TROUBLESHOOTING amp REPAIR STATIC SCR DIODE RECTIFIER BRIDGE TEST continued FIGURE F 15 HEAT SINK AND SCR TEST POINTS REMOVE INSULATING PAINT T 10 Remove the red insulating paint from the heat sink test points See Figure 15 NOTE Do not disassemble the heat sink
80. d the technician in mounting stud type diodes to the alu minum heat sinks on the R3R MATERIALS NEEDED 5 16 Nut driver 1 2 Open end wrench Lincoln E1868 Dow Corning 340 Heat Sink Compuond Slip type torque wrench No 000 fine steel wool 7 2 This procedure takes approximately 20 minutes per diode to perform 8 E Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 53 53 TROUBLESHOOTING amp REPAIR O10 E e MOUNTING OF STUD TYPE DIODES TO ALUMINUM 515 HEAT SINKS continued olg 2 cle PROCEDURE 1 Remove the main input supply power to the DIODE STUD FOOT INCH 5 SIZE POUNDS POUNDS oc 2 With the 5 16 nut driver remove the case 3 4 16 25 27 300 324 top and sides 1 10 5 25 3 Loosen the appropriate diode nut remove the diode that is to be replaced 4 Clean the area on the heat sink around the diode mounting surface using a putty knife or similar tool DO SCRATCH THE DIODE MOUNTING SURFACE 5 Polish each heat sink s mounting surface using No 000 fine steel wool Wipe the sur face clean with a lint free cloth or paper towel 6 Inspect the mounting surfaces of each new diode Remove all burrs and wipe clean Do not use steel wool or any abrasive cleanser on the diode mounting su
81. dations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations IDEALARC R3R LINCOLN 7 2 PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions 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 suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter tou jours 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 b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un planch er 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 c Maintenir le porte lectrode la pince de masse le cable de soudage et la machine souder en bon et s r tat defonctionnement d jamais plonger le porte lectrode dans l eau pour le refroidir e ja
82. de spring The different designs require different assembly and clamping procedures The assem bly procedure will be different depending upon the thread on the cap screws 1 4 28 thread requires a different tightening procedure than a FA HOUSING HEAT SINK Return to Section TOC Return to Master TOC 1 4 20 thread LEAF SPRING PROCEDURE FOR THE 1 2 INCH WIDE CF SPRING 1 Place a piece of sleeving around each cap screw CAP SCREW 2 Insert cap screws through the leaf spring Orient the leaf spring so that its ends are curved upward toward the cap screw heads See F 29 Pressing on the cap screw heads should produce a rocking motion of the spring in its housing If the spring does NOT rock it is installed upside down Remove the spring and turn it over Check for rocking motion See Figure F 29 o Fle 515 0 gt 2 1 3 Insert cap screws leaf spring into the plastic housing 4 Insert clamp assembly through heat sinks Install nuts Tighten clamp nuts equally on cap screws until finger tight See Figure 0 Heat sinks may not be exactly as pictured 5 Reinspect the SCR for proper seating Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E
83. ductive harm The Above For Diesel 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 The Above For Gasoline Engines Return to Master TOC Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 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 Return to Master TOC o D 2 Return to Master TOC FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 b Operate engines open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts
84. dures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input contactor is receiving the correct DC coil voltage and if the contacts are functioning correctly Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver IDEALARC R3R Wiring Diagrams See the Electrical Diagrams section of this manual External 120VDC supply This procedure takes approximately 20 minutes to perform Fle 5 0 lt 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC o 7 2 14 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 3 DC COIL INPUT CONTACTOR CONNECTIONS 232 TEST PROCEDURE 1 Disconnect the main input supply power to the machine 2 With the 5 16 nutdriver remove the case top and the reconnect panel cover 3 Locate the two leads connected to the input contactor coil
85. e 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 upright 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 hot 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 Oylinders 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 recommen
86. ection TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in gaining access to the fan blade and fan motor for maintenance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 3 8 Wrench Allen head type wrench This procedure takes approximately 30 minutes to perform Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 42 F 42 TROUBLESHOOTING amp REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT continued FIGURE F 26 FAN MOTOR MOUNTING DETAILS MOUNTING BRACKETS PROCEDURE 1 Remove the main input supply power to the machine Using the 5 16 nut driver remove the case top and sides The fan blade can be removed using the Allen head wrench NOTE You may need to loosen the machine case back to gain clearance to remove the fan See Figure F 26 If
87. efore welding 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 minimize exposure to EMF fields from the welding circuit 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 2 d 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 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 2 d 5 Do not work next to welding power source IDEALARC R3R LINCOLN 7 2 ELECTRIC SHOCK can kill 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 location
88. emperature The amber thermal protection indicator light will turn on until the machine cools 60 Duty Cycle Amps Volts 300 300 32 400 400 36 500 500 40 Based a 10 minute time period For example a 60 duty cycle means 6 minutes on and 4 minutes off IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC B 4 OPERATION CONTROLS AND SETTINGS All operator controls and settings are located on the case front assembly See Figure B 1 for their loca tions 3 FIGURE 1 CASE FRONT CONTROLS Power Source Pilot Light ON OFF Power Toggle Switch Arc Force Control Current Range Selector Switch not on R3R 300 Output Control Potentiometer Output Control Switch with or Remote positions 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 ON OFF POWER TOGGLE SWITCH Energizes or de engergizes the input contactor which is pow ered by the 115 volt auxiliary transformer The switch turns the machine ON OFF Position 41 is ON position 0 is OFF ARC FORCE SELECTOR Allows you to select the ideal arc force according to the procedure and electrode being used fo
89. et Amptrol board See Figure F 22 Check pin 1 green lead to pin 2 yellow lead Normal is approximately 12VAC Check pin 3 green lead to pin 2 yellow lead Normal is approximately 12VAC If the correct primary voltage is applied to the T3 transformer and either of the secondary voltages are missing or low the T3 trans former may be faulty Turn off the R3R machine Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 3 o 7 2 33 TROUBLESHOOTING amp REPAIR POCKET AMPTROL CIRCUIT TEST continued FIGURE F 22 POCKET AMPTROL BOARD PLUG P6 AND P7 LOCATION Pin 3 Green Pin 1 Green Pin 2 Yellow Pin 1 Lead 218 Pin 2 Lead 219 8 Connect the Pocket Amptrol unit from the work to the electrode welding output termi nals Jumper wires may be necessary WARNING Electric Shock can kill With the input power on there are high volt ages inside the machine Do not reach into the machine or touch any internal part of the machine while the power is on 9 Turn on the R3 machine 10 Check for the following voltages at plug P6 pin 1 lead 218 to pin 2 lead 219 Plug 6 is located on the Pocket Amptrol board See Figure F 22 a With the Pocket Amptrol in posi
90. g of the power SCR is mounted Also note the positioning of the gate lead of the SCR Failure to reinstall the new SCR in the same ori entation as the original may result in subsequent damage to the new SCR and other components of the welder See Figure 28 CAUTION The unclamping and clamping procedure out lined below is critical for the prevention of inter nal SCR damage Failure to follow this proce dure may result in subsequent damage of the SCR Handle all SCRs with care PROCEDURE 1 Remove the main input supply power to the machine 2 Perform SCR Diode Rectifier Assem bly Removal procedure 3 Using the 7 16 wrench remove the NEGA TIVE heat sink plate Diode D4 pigtail will have to be removed from the positive heat sink plate This will give access to the SCR clamping hardware When reassembling be sure all insulators are in place The heat sink plate should be electrically insulated from the mounting thru bolts IN Alternately loosen nuts 1 2 turn each until heat sinks are loose Remove nuts and leaf spring IT 1 RECOMMENDED THAT NEW HARDWARE LEAF SPRING AND HOUSING BE USED FOR REASSEMBLY 5 Remove the old SCR 6 Clean the area on the heat sink around the SCR mounting surface using a putty knife or similar tool DO NOT SCRATCH THE SCR MOUNTING SURFACE 7 Polish each heat sink s mounting surface using NO 000 fine steel wool Wipe surface clean with a lint free cloth or paper towel
91. hem until installation is complete f you return a PC Board to The Lincoln Electric Company for credit it must be in the static shielding bag This will prevent further damage and allow proper failure analysis 4 Test the machine to determine if the failure symp tom has been corrected by the replacement PC board NOTE Allow the machine to heat up so that all elec trical components can reach their operating temperature 5 Remove the replacement PC board and substitute it with the original PC board to recreate the original problem a If the original problem does not reappear by substituting the original board then the PC board was not the problem Continue to look for bad connections in the control wiring harness junction blocks and termi nal 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 IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 3 Return to Section TOC Return to M
92. his switch should not be changed while welding Fle 515 PEN 2 818 5 5 1 The Pocket Amptrol option provides the operator with wireless remote current control capabilities The cir cuit is powered by the optional amptrol transformer which has a 115VAC primary winding and a 24VAC tapped secondary winding control board receives command information from the voltage sens ing network located on the positive output lead This information is processed on the Pocket Amptrol PC board and the current control signal is sent to the board Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 515 0 gt 2 1 Return to Section TOC Return to Master TOC E 5 E 5 THEORY OF OPERATION PROTECTIVE DEVICES AND CIRCUITS Two thermostats protect the R3R from excessive operating temperatures and overload conditions Excess operating temperatures may be caused by insufficient 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 other is mounted on the choke assembly These two thermostats are connected in series with the input contactor coil If either of the thermostats opens the input contactor will be de e
93. ke it is loaded Operating the machine beyond the current rating will cause the overload protection circuit on the control board to phase back the machine to a low out put Make sure the fan motor and blades are operating properly Check the output shunt for loose or faulty connections The output shunt may be faulty Replace The control board may be faulty Replace Perform the SCR Diode Rectifier Bridge Test Perform Main Transformer Check the latching resistor R3 Normal resistance is 40 ohms CAUTION If for any reason you do not understand the test procedures are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 E Return to Section TOC Return to Master TOC o 2 TROUBLESHOOTING 4 REPAIR Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS SYMPTOMS Poor arc characteristics The welding arc is variable and sluggish POSSIBLE AREAS OF MISADJUSTMENT S WELDING PROBLEMS Make sure the correct weld pro cedures being used Electrode
94. l See Figure F6 b Connect the other end of the alligator clip to one of the meter probes Be sure that neither the alligator clip nor the meter probe touches any metal surfaces c Connect the other meter probe to the 231 connection at the power switch See Figure d Apply input power to the R3R 7T Read the meter for 115VAC a If 115VAC is present the control trans former is functioning properly b If 115VAC is NOT present go to Step 8 IDEALARC R3R LINCOLN 8 FIGURE F 6 CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS INSULATED ALLIGATOR CLIP CABLE INPUT CONTACTOR CASE BACK If 115VAC is not present between leads X1 and 231 check the spliced connection between 231 and X2 Test for correct main input supply power to the control transformer primary windings H1 H2 H3 etc Check the main input supply power hookup to the machine See the Wiring Diagram If the correct main input supply power to the control transformer primary windings is present AND the secondary voltage is not correct the control trans former may be faulty Replace Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC 7 2 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTA
95. lder is removed from the circuit and its setting has no effect on the ouput With the CURRENT RANGE SELECTOR switch in the range posi tion the pocket amptrol provides total control from minimum to maximum output of the welder b Turn the welder POWER switch ON c Insert one end of the probe into the electrode hold er and hold the other end on the work for approxi mately five seconds d To change current change the probe dial setting and repeat the five second procedure of placing the probe between electrode and work The solid state circuitry within the welder senses this change in probe setting and automatically resets the welding current to the new level Each time the welder is turned off the output goes to minimum and must be reset when the welder is turned on again IDEALARC R3R LINCOLN Section C 1 Section C 1 TABLE OF CONTENTS ACCESSORIES SECTION 2 ACCESSO OS onorarii Section 5 5 0 5 2 5 Factory Installed Options E odas Y REA C 2 Polarity Switch m 2 2 Pocket AmpltoL tace IRIS MEHR 2 Field Installed Optlons C 2 Remote Output Adapter Cable 857
96. louvers Keep dust dirt and other foreign materials that can be drawn into the machine to a minimum Failure to observe these pre cautions can lead to excessive operating temperatures and nuisance shut downs LIFTING WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using the lift bail if it is equipped with a heavy accessory such as a trailer or a gas cylinder e Lift only with equipment of adequate lifting capacity Be sure the machine is stable when lifting Do not stack more than three high Do not stack the R3R on top of any other machine A permanent lift bail is located at the top of the machine positioned at the center of gravity for stable lifting weights are as follows R3R 300 350 pounds 159 kilograms 400 402 pounds 182 kilograms R3R 500 446 pounds 202 kilograms TILTING Place the machine on a secure level surface Any sur faces you place it on other than the ground must be firm non skid and structurally sound STACKING Idealarc R3Rs may be stacked three high The bottom machine must be on a stable hard level surface capa ble of supporting the weight of up to three machines 1350 pounds 1608 kilograms Be sure that the two pins in the roof of the bottom machine fit into the holes in the base of the machine above The lift bail is posi tioned so that it fits without interference under the base of the second machine Do not stack heavier
97. lso check for any other condition that could affect the proper operation of the machine Perform periodically 1 In extremely dusty conditions dirt may clog the cooling air channels causing the machine to run hot Blow out the machine at regular intervals with low pressure air Clean the following parts See Figure D 1 Main transformer and choke SCR diode bridge Control PC board Electrode and work cable connections Fan assembly NOTE The fan motor has sealed bearings that require no service Remote control terminal strip TS1 in machines below code 9500 NOTE Keeping remote control terminal strip TS1 clean is especially important in damp locations 2 Pocket Amptrol Maintenance Clean and maintain the optional Pocket Amptrol if equipped Keep the probe tip in good condition It requires sharp edges to penetrate heavy oxide coatings on the work piece A blunted tip could result in different welding currents for a given dial setting IDEALARC R3R LINCOLN 5 0 3 j A V Tex lt SS NC 5 142 VL ME Z Q 9 lt 5 Z lt lt gt 5 g 5 5 9 O54 og 290 99 25 E dr OE os ut ok 225 93
98. m Idle KW 200 3 60 0 92 208 3 60 0 92 230 3 60 0 92 400 3 60 0 92 440 3 60 0 92 460 3 60 0 92 480 3 60 0 92 575 3 60 0 92 200 3 50 220 3 50 380 3 50 400 3 50 415 3 50 425 3 50 440 3 50 500 3 50 550 3 50 Return to Section TOC Return to Master TOC Lm L A E cA ck ck OPEN CIRCUIT VOLTAGES Test Points Input Hertz Open Circuit Volts Welding Output Terminals 60 63 68VDC Welding Output Terminals 50 61 65VDC O o Fle 5 5 0 PEN 8 1 WELDING OUTPUT LOAD TEST Output Control Settings Volts Current Control at 20VDC Maximum Minimum Current Control at 39 to 45 VDC Maximum Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 62 62 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR 400 Retest a machine e f it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 1 04 208 3 60 1 04 230 3 60 1 04 380 3 60 1 04 440 3 60 5 1 04 460 3 60 5 1 04 550 3 60 1 04 575 3 60 1 04 200 3 50 220 3 50 230 3 50 380 3 50 400 3 50 415 3 50 440 3 50 500 3 50 550 3 50
99. mais toucher simultan ment les parties sous ten sion des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps 3 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 b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnementde l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons 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 o l on pique le laitier 6 les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie tincelles 2 Aut
100. manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the main transformer for mainte nance or replacement Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 9 16 Socket wrench 9 16 Box end wrench 1 2 Socket wrench 1 2 Box end wrench 3 8 Nut driver or socket wrench 9 16 Deep well socket wrench This procedure takes approximately 3 to 5 hours depending on which coils are being replaced Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 55 F 55 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE F 33 LIFT BAIL REMOVAL FIBER BAFFLES BASE MOUNTING BOLTS 4 MAIN TRANSFORMER REMOVAL OF LIFT BAIL 1 Remove the main input supply power to the machine With the 5 16 n
101. mm 840 mm 159 kg IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 gt 1 Return to Section TOC Return to Master TOC INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC 400 INPUT THREE PHASE ONLY Standard Voltage Input Current Rated Output 230V 74 460 37A RATED OUTPUT Duty Cycle Volts at Rated Amps 10096 32 6096 36 3596 40 OUTPUT Current Range Maximum Open Circuit Voltage 60 to 500 Amps 67 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES 60 DUTY CYCLE Input Wire Size Ground Wire Size Input Voltage Fuse Input Ampere Type 75 C Type 75 C Frequency Super Lag Rating on Copper Wire in Copper Ground or Breaker Size Nameplate Conduit Wire in Conduit Volts Hz AWG IEC Sizes AWG IEC Sizes 230 60 6 16 6 16 mm 460 60 10 6 10 6 mm PHYSICAL DIMENSIONS Height Depth Weight 27 50 in 33 10 in 402 Ibs 700 mm 840 mm 182 kg IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC O10 515 0 gt 1 Return to Section TOC Return to Master TOC 4 4 INSTALLATION TECHNICAL SPECIFICATIONS IDEALARC 500 INPUT THREE PHASE ONLY Standard Voltage Input Current Rated Output 230V 88A 4
102. nals to the SCR diode bridge This creates a DC voltage at the output of the bridge assembly This DC voltage is applied through the output choke to the output termi nals The output choke which is in series with the negative output terminal stores energy and provides current filtering for the constant current welding arc O o Fle 515 PEN 2 818 E 5 5 1 NOTE Unshaded areas of Block Logic Diagram are the subject of discussion IDEALARC R3R LINCOLN P Return to Section TOC Return to Master TOC 4 4 o 8 FIGURE E 4 OPTIONAL POLARITY SWITCH AND AMPTROL CIRCUITS 5 5 T o 5 B 5 5 Serica TRANSFORMER AMPHENOL 7 OUTPUT STRIP ARC FORCE DIAL CONTROL TRANSFORMER FEEDBACK NEGATIVE OUTPUT TERMINAL THERMOSTATS 2 1 OPTIONAL Return to Section TOC Return to Master TOC R POLARITY 4 E L SWITCH E C N k T 1 INPUT SCR DIODE HYBRID BRIDGE TERMINAL OPTIONAL POLARITY SWITCH AND POCKET AMPTROL CIRCUITS The polarity switch permits changing the arc polarity at the output terminals of the machine T
103. nergized and the main transformer will be removed from the input line The amber High Temperature Light will turn on and the machine will remain inoperative until the thermostats cool and reset The R3R power sources are also protected against output current overloads This overload protection circuit located on the control board will reduce the welding current to a safe level if the machine is over loaded for two or three seconds If the control leads are accidentally grounded or short ed to the case of the machine the welding output will be low and no damage should occur to the control board circuitry IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Fle 5 5 0 lt 2 1 Return to Section TOC Return to Master TOC E 6 E 6 THEORY OF OPERATION FIGURE E 5 SCR Operation INPUT CATHODE GATE SCR OPERATION A silicon controlled rectifier SCR is a three terminal device used to control rather large 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 from anode to cathode the ON state the SCR acts like a closed switch When the SCR is turned OFF there is no current flow from anode to cathode thus the device acts like an open switch As the name suggests the SCR is a rectifier so it passes curre
104. nes 1 Perform the nput Contactor 2 Check the associated leads for loose or faulty connections between the input contactor CR1 the reconnect panel and the main transformer See the Wiring Diagram 3 Perform the Main Transformer CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC R3R LINCOLN 5 F 5 F 5 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS The machine is dead no output If the amber thermal protection 1 Check the leads and connec no fan The input contactor does light is on the primary or sec tions between the thermostats not operate The amber thermal ondary thermostat is open the input contactor 1CR and protection light is on The pilot Allow the machine to cool the power switch SW1 See light is on Check the fan motor for proper the Wiring Diagram operation Make sure all case openings are free for proper cir culation of air Operate the machine at rated current and duty cycle Return to Section TOC Return to Master TOC One of the normally closed thermostats may be
105. ng See the Wiring Diagram Perform the Main Transformer Perform the SCR Diode Rectifier Bridge Test If the Pocket Amptrol is not functioning properly perform the Pocket Amptrol Circuit The control board may be faulty Replace The input contactor operates the fan runs the pilot light is on but the machine has no welding out put The open circuit voltage is not present at the output terminals Make certain the output control switch SW2 is in the Machine or Local position If the prob lem is resolved check the remote control and associated circuitry See the Wiring Diagram 2 3 4 Check for loose or faulty con nections on the heavy current carrying leads between the out put terminals the shunt the choke and the SRC Diode Bridge See the Wiring Diagram Perform the SCR Diode Rectifier Bridge Test Perform Main Transformer The control board may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 5 2 E o 7 2
106. nt only during positive half cycles of the AC supply The positive half cycle is the portion of the sine wave in which the anode of the SCR is more pos itive than the cathode When an AC supply voltage is applied to the SCR the device spends a certain portion of the AC cycle time in the ON state and the remainder of the time in the OFF state The amount of time spent in the ON state is controlled by the gate Z A _ NOTE AS THE GATE LATER IN THE CYCLE THE SCR OUTPUT IS DECREASED 1 An SCR is fired a short burst of current into the gate This gate pulse must be more positive than the cathode voltage Since there is a standard PN junc tion between gate and cathode the voltage between these terminals must be slightly greater than O 6V Once the SCR has fired it is not necessary to contin ue the flow of gate current As long as current contin ues to flow from anode to cathode the SCR will remain on When the anode to cathode current drops below a minimum value called holding current the SCR will shut off This normally occurs as the AC sup ply voltage passes through zero into the negative por tion of the sine wave If the SCR is turned on early in the positive half cycle the conduction time is longer resulting in greater SCR output If the gate firing occurs later in the cycle the conduction time is less resulting in lower SCR output IDEALARC R3R LINCOLN 5
107. ntrol choke and solid state control system deliver outstanding arc characteristics For stick weld ing an Arc Force Control enables the Idealarc R3R to create a soft welding arc for critical applications or a forceful driving arc for heavy duty applications RECOMMENDED PROCESSES The Idealarc R3R is recomended for stick and DC TIG welding and air carbon arc gouging DESIGN FEATURES AND ADVANTAGES Input line voltage compensation keeps output con stant for fluctuations of 10 Hinged front control panel provides easy access to printed circuit boards and other control circuitry Fully enclosed fan motor with permanently lubri cated sealed ball bearings needs no maintenance Fully recessed control panel protects controls and minimizes accidental contact Recessed output terminals reduces chance of acci dental contact ow profile case permits installation under a work bench Removable rear access panel provides easy access to input contactor and input lead connections Removable case sides provide easy access for ser vice or inspection even when machines are stacked Dripproof enclosure design permits outdoor operation Double dipped transformer SCR bridge and choke resist corrosion WELDING CAPABILITY The Idealarc has the following duty cycle ratings If the duty cycle is exceeded a thermal protector will shut off the machine output until it cools to normal operating t
108. o Master TOC IDEALARC R3R LINCOLN F 22 F 22 TROUBLESHOOTING amp REPAIR 5 TRANSFORMER T1 VOLTAGE TEST continued 55 9 8 o PHASE ANGLE WINDING TEST o 12 Test with an voltmeter approximate NOTE f the main input supply voltage 3 ly 66VAC at each phase winding Test varies the main transformer voltages will leads 201 202 203 and 204 per vary proportionately Ifthe voltage is low remove the plug or For control board G2206 see Figure 9 leads and recheck the voltage for for lead locations 66VAC f the reading is normal the control board may be faulty Replace For control board 91575 see Figure 10 th control board for lead locations b If one or more of the voltage tests are incorrect check for loose or faulty wiring c f the wiring is good then the main transformer may be faulty Replace the main transformer Return to Section TOC Return to Master TOC Fle 5 0 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 23 23 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 9 CONTROL BOARD G2206 TEST POINTS Return to Section TOC Return to Master TOC Plug P4 Plug P3 2 3 Return to M
109. ocedure takes approximately 15 minutes to perform The replacement procedure takes approximately 25 minutes to perform IDEALARC R3R LINCOLN F 39 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 40 F 40 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR CR1 CLEANING REPLACEMENT continued FIGURE 25 INPUT CONTACTOR CLEANING AND REMOVAL T3 0112 T2 T1 1 INPUT SUPPLY LINE 2 INPUT CONTACTOR CR1 3 RECONNECT PANEL CLEANING PROCEDURE 1 Remove the main input supply power to the machine Locate and get access to the input contac tor CR1 in the input box See Figure 25 Remove the input contactor cover plate using a phillips head screwdriver A WARNING Do not apply input power to the machine with the input contactor cover plate re moved Blow out any dirt or dust in or around the contacts with a low pressure air stream Inspect the contacts for signs of excessive wear pitting or contacts fused stuck together any of these conditions are present replace the input contactor assembly Replace the input contactor cover plate CONTACTOR REPLACEMENT PROCEDURE 1 Disconnect main input
110. of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b 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 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 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
111. ost likely component caus ing the failure symptom 2 Check for loose connections at the PC board to assure that the PC board is properly connected 3 If the problem persists replace the suspect PC board using standard practices to avoid static electrical damage and electrical shock Read the warning inside the static resistant bag and perform the following procedures PC Board can be damaged by static electricity Remove your 5 static charge before opening the static shield ing bag Wear an anti static wrist strap For safety use a 1 Meg Aa ATTENTION de Static Sensitive ohm resistive cord connected to a Devices grounded part of the equipment Handle only at frame Static Safe f you don t have a wrist strap touch an unpainted grounded part of the equipment frame Keep touching the frame to pre vent static build up Be sure not to touch any electrically live parts at the same time Workstations Reusable Container Do Not Destroy Tools which come in contact with the PC Board must be either conductive anti static or static dissipative Remove the PC Board from the static shielding bag and place it directly into the equipment Don t set the PC Board on or near paper plastic or cloth which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag f the PC Board uses protective shorting jumpers don t remove t
112. other irritating products Shielding gases used for arc welding can displace air and cause 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 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 IDEALARC R3R LINCOLN amp D 2 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 tou
113. ou do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will determine if the correct voltage is being applied to the primary of the control transformer and induced on the secondary winding of the control transformer Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver IDEALARC R3R Wiring Diagrams See the Electrical Diagrams section of this manual This procedure takes approximately 17 minutes to perform o Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 17 17 TROUBLESHOOTING 4 REPAIR CONTROL TRANSFORMER T2 VOLTAGE TEST continued FIGURE 5 CONTROL TRANSFORMER AND LEAD LOCATIONS LEAD X1 CONNECTION Return to Section TOC Return to Master TOC INPUT CONTACTOR 2 3 LEAD X2 CONNECTION SPLICED TO LEAD 231 9 TEST PROCEDURE 5 1 Disconnect main input supply power to 5 Locate control transformer leads X1 top 9 the machine and X2 2 2 With the 5 16 nut driver remove the top a Lead X1 is
114. pment may result in danger to the technician or 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the SCRs from the output rect ifier heat sink for maintenance or replacement MATERIALS NEEDED NO 000 Fine Steel Wool Penetrox 13 Lincoln E2529 or Penetrox A 7 16 Open end wrench Allen head type wrenches This procedure takes approximately 25 minutes to perform IDEALARC R3R LINCOLN F 46 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 3 Return to Section TOC Return to Master TOC 7 2 47 47 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT continued FIGURE F 28 SCR DETAILS GATE ANODE CATHODE OUTER METAL RING SPECIAL INSTRUCTIONS NOTE Before disassembling the existing recti fier note toward which heat sink the outer metal rin
115. ponsibility for liablilities resulting from board level troubleshooting PC Board repairs will invalidate your factory warranty Individual Printed Circuit Board Components available from Lincoln Electric This information is provided for reference only Lincoln Electric discourages board level troubleshooting and repair since it may compromise the quality of the design and may result in danger to the Machine Operator or Technician Improper PC board repairs could result in damage to the machine G 6 R3R 5 5 oc 32 c SAHN3H 50151634 aps SLIOA GAW SHOLIOVdVO etc 85 s 52 2 elg ros 9 1 1 7 7 fog 8T Ov9ETI 2 Gdl ree 21 09511 _ gs MS 62 89711 6 g LEG C9 B i 1 cr 009750 95 19111 2 00v GAN 8970 89 44911 11 2319 gt qu 49 3 I NOLLVOIJILN3GI ON 0034 WALI 5 2 25 gt gt lt c t
116. r CC stick It controls the amount of current added to the welding current when the electrode shorts to the work At mini mum setting no extra short circuit current is added The arc will be softer and have less spat ter but may be more prone to sticking At maxi mum setting the arc will be more forceful and less prone to sticking but will produce more spatter For TIG welding applications this control should usually be set to minimum 7 8 9 0 4 Remote Control Connections 6 amphenol or terminal strip Polarity Switch optional DC Ammeter optional DC Voltmeter optional Thermal Protection Indicator Light CURRENT RANGE SELECTOR SWITCH R3R 400 and 500 only position selects lower range current control position selects higher range current control OUTPUT CONTROL SWITCH OR REMOTE POSITIONS Selects the mode of control In the position control is by the machine control panel In the Remote position control is through an optional remote control device OUTPUT CONTROL POTENTIOMETER trols current REMOTE CONTROL CONNECTION The 6 pin amphenol receptacle provides remote control con nections Machines below code 9500 use a termi nal strip instead of the amphenol A strain relief connector is provided for cable entry IDEALARC R3R LINCOLN 5 8 POLARITY SWITCH optional Permits chang ing the
117. r should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or 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 Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD 55 gt 8 DESCRIPTION 5 This test will help determine if the device be gated ON and conduct current from anode amp to cathode MATERIALS NEEDED An SCR tester as specified in this procedure 5 16 Nut driver Idealarc R3R Wiring Diagrams See the Electrical Diagrams section of this manual This procedure takes approximately 30 minutes to perform Fle 5 0 PEN ele 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN P Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 E Return to Section TOC Return to Master TOC 0
118. rackets 15 Reattach the three heavy aluminum secondary leads and snubber leads to the SCR finned heat sinks Apply a thin coating of Dow Corning 340 heat sink compound to connection points 16 Attach plug J4 or individual gate leads to the control board 17 Attach the positive lead and shunt to the positive heat sink plate 18 Attach the two 220 leads to the right side of the negative heat sink plate 19 Connect the choke switch lead to the left side of the negative heat sink plate See Figure 27 20 Install the glastic stiffeners to the left and right sides See Figure F 27 21 Attach the air deflector to the front panel R3R 500 See Figure 27 22 Check all lead placements and secure Return to Section TOC Return to Master TOC 23 Attach the front assembly to the machine s base 24 Install the front control panel and case top and sides Fle 5 0 PEN 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC Return to Master TOC F 46 TROUBLESHOOTING amp REPAIR SCR REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equi
119. rent control provides the same dial range as the current control on the welder Consists of a 6 pin Amphenol connector which plugs into the remote control Amphenol Accessory Kits For RSR 300 and RSR 400 Consists of electrode and work cables headshield electrode holder and work clamp R3R 300 K703 R3R 400 K704 Undercarriage K817P A mounting frame with wheels for hand moving Undercarriage K841 Platform undercarriage with mountings for two gas cylinders at rear of welder TIG WELDING OPTIONS TIG Module K930 2 Portable high frequency unit with gas valve for TIG welding Rated at 300 amps 60 duty cycle Request publication E3 205 Water Valve Kit K844 1 For use with a water cooled TIG torch Controlled by the preflow and after flow timers Installs inside the TIG module Amptrol Provides 25 ft 7 6m of remote current control for TIG welding 6 pin MS type plug connec tion Foot Amptrol K870 Hand Amptrol K963 1 Hand Amptrol K963 2 Contactor Kit K938 1 For use with the TIG Module Docking Kit K939 1 Secures TIG Module on top of R3R machines or any flat surface at least 10 in x 15 in 254mm x 381mm Mounts using strong grip adhe sive pad or fasteners Includes latch and provisions for a user supplied padlock Control Cable K936 3 Connects the TIG Module to the R3R machine 9 to 6 plus 115V plug Control Cable Extensions Allows the TIG Module to be operated
120. rface 7 Apply a thin 0 003 to 0 007 uniform layer of E1868 Dow Corning 340 heat sink com pound to the heat sink mounting surface Return to Section TOC Return to Master TOC a Do not apply compound to the diode stud or mounting threads b The diode threads must be clean and free of defects so that the nut can be fin ger tightened before applying torque A slip type torque wrench must be used to tighten the diode nut 8 Tighten the diode nuts to the specifications in the following table Fle 5 5 0 PEN 2 1 Start the nuts for diodes with steel studs by hand and then torque them accord ing to the following table b Run the nuts for diodes with copper studs on all the way by hand then torque them according to the following table c Turn the nuts a minimum of 1 2 turn more while torquing 9 Install the case top and sides Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 54 54 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this
121. s 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 semiautomatic 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 and 8 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
122. s that clamp the top iron to the bottom E iron Lightly tap on the top of the iron with a hammer before tightening Tighten the nuts and thru bolts to 19 25 Ib ft FIGURE F 37 COIL INSULATION PRIMARY COILS TOP LEFT TOP CENTER TOP RIGHT SECONDARY COIL ASSEMBLY INSULATION PRIMARY COIL BOTTOM SHIMS IDEALARC R3R LINCOLN F 59 F 59 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued 10 If necessary trim off excess secondary lead stickout and TIG weld the leads together See Figure F 38 Return to Section TOC Return to Master TOC FIGURE F 38 SECONDARY LEAD TRIM AND WELD DETAIL Return to Section TOC Return to Master TOC O10 515 0 gt 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN F 60 F 60 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued REASSEMBLING THE MAIN REASSEMBLE THE LIFT BAIL TRANSFORMER INTO THE MACHINE 4 NOTE The following procedure assumes you have completely reassembled the transformer coils as described in the procedure above The lower iron has remained in place in the 2 Using the 9 16 socket wrench attach the lift bail to machine See Figures 2 27 the transformer top and bottom irons with four 1 Resolder the choke thermos
123. serve all safety notes and precautions detailed throughout this manual Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION This test will help determine if the input contactor is receiving the correct AC coil voltage and if the contacts are functioning correctly Return to Section TOC Return to Master TOC MATERIALS NEEDED Volt Ohmmeter Multimeter 5 16 Nut driver IDEALARC Wiring Diagrams See the Electrical Diagrams section of this manual External 120VAC supply This procedure takes approximately 20 minutes to perform Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 8 3 Return to Section TOC Return to Master TOC o 7 2 11 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE F 1 AC COIL INPUT CONTACTOR CONNECTIONS X1 4232 TEST PROCEDURE 1 Disconnect the main input supply power
124. t forward to make room for the removal of the SCR diode bridge assembly Remove the two screws holding the air deflector 500 only to the front panel Remove the air deflector Remove the glastic stiffeners one on each side left and right See Figure E27 Remove the choke from the left side of the negative heat sink plate See Figure 27 IDEALARC R3R LINCOLN 5 10 11 12 CHOKE Remove the two 220 leads from the right side of the negative heat sink plate Remove the positive lead and shunt from the positive heat sink plate See Figure 27 Remove the gate leads from the control board either plug J4 or individual gate leads Remove the three heavy aluminum sec ondary leads and snubber leads from the SCR finned heat sinks Note lead placement for reassembly Remove the four nuts and associated wash ers that hold the SCR diode assembly to the mounting brackets Carefully lift and remove the SCR diode heat sink assembly from the machine Clear any necessary leads that might hinder removal 45 45 TROUBLESHOOTING SCR DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT continued REASSEMBLY 13 For reassembly carefully place the SCR diode assembly into position on the mounting brackets Return to Section TOC Return to Master TOC 14 Replace and tighten the four nuts and lockwash ers that hold the SCR diode assembly to the mounting b
125. tat lead bolts 3 Install resistor R3 40 ohms 100 watts Carefully position the lift bail onto the machine base Using the 9 16 socket wrench attach the lift bail to the base of the machine with four bolts flat washers and lock washers Return to Section TOC Return to Master TOC 2 Attach the bottom choke lead to the negative recti fier plate Attach the top choke lead to the polarity selector Switch or the negative output terminal If the optional Pocket Amptrol diodes are installed resolder the leads to the shunt and the optional polarity switch Resolder leads 218 and 219 to the sensing resistor 5 Attach the fiber baffles to the left and right sides of the choke 6 Reattach any transformer coil connections that were previously removed 7 Install the machine case top and sides Return to Section TOC Return to Master TOC Fle 5 5 0 PEN 2 1 Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN 61 61 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR R3R 300 Retest a machine e f it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine s electrical characteristics OR f you repair or replace any electrical components Return to Section TOC Return to Master TOC INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximu
126. the fan motor is to be removed the leads to the motor must be disconnected This will require cutting the wires or breaking the splice SHROUD ATTACHED TO CASE BACK Remove the four mounting nuts and associ ated flat and lock washers that hold the motor to the mounting bracket See Figure 26 Carefully remove the fan motor 7 To replace the fan motor mount the motor to 10 IDEALARC R3R LINCOLN its mounting bracket using the four nuts and associated flat and lock washers Resplice any motor leads cut for removal Soldering the wires is recommended Reattach the fan blade if it was removed earlier using the Allen head wrench to tighten it to the motor shaft Install the case top and sides 43 43 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT WARNING Return to Section TOC Return to Master TOC Service and repair should be performed by only Lincoln Electric factory trained personnel Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for elec
127. tion 1 the voltage should be approximately 40 8mV b With the Pocket Amptrol in position 10 the voltage should be approximately 138 9mV If the correct AC voltages are applied to the PC board and the correct DC mV is sensed at plug P6 pins 1 and 2 the Pocket Amptrol circuit should function properly If it does NOT check the leads between the plug P6 leads 75 76 and 77 see Figure 24 and the local remote switch SW2 See the Wiring Diagram If the leads are OK the PC board may be faulty If the correct AC voltages are applied to the PC board and the DC mV are not cor rect check the sensing resistor R4 See Figure F 23 and the Wiring Diagram Normal resistance is 0 4 ohms If the resistance at R4 is normal 0 4 ohms the Pocket Amptrol board may be faulty Return to Section TOC Return to Master TOC IDEALARC LINCOLN 34 34 TROUBLESHOOTING amp REPAIR POCKET AMPTROL CIRCUIT TEST continued 9 gt FIGURE 23 SENSING RESISTOR R4 9 8 E E ala 2 Sl EP XZ 515 o olg 5 218 SENSING RESISTOR ala 2 FIGURE 24 AMPTROL SIMPLIFIED DRAWING POSITIVE OUTPUT 9 NN
128. to the machine 2 With the 5 16 nut driver remove the case top and the reconnect panel cover 3 Locate the two leads connected to the input contactor coil 233 and X1 232 top See Figure F 1 for location 4 Connect an AC voltmeter to the leads Electric Shock can kill With the input power there are high voltages inside the machine Do not reach the machine or touch any internal part of the machine while the power is on IDEALARC R3R LINCOLN P Apply the correct voltage to the machine and turn the power switch S1 ON Check for 120VAC at the contactor coil leads If the 120VAC is NOT present with the power switch S1 on check the power switch 81 thermostat and associated cir cuitry See the Wiring Diagram Also per form the Control Transformer T2 Voltage If the 120VAC is present and the contactor does NOT activate then the input contactor is faulty Replace the input contactor 12 12 TROUBLESHOOTING amp REPAIR INPUT CONTACTOR TEST continued FIGURE 2 AC COIL INPUT CONTACTOR TEST POINT LOCATIONS Return to Section TOC Return to Master TOC X1 232 APPLY 2 EXTERNAL 8 19 120 5 5 1 232 5 8 233 233 1 TEST FOR CONTACT CONTINUITY 1 Disconnect the main input supply power to 4 With the contactor activated check the
129. to maximum output is obtained with a single potentiometer control INPUT LINE VOLTAGE CONTACTOR AND MAIN TRANSFORMER The desired three phase input power is connected to the R3R through an input contactor located in the input box at the rear of the machine Two phases of the input line are also connected to the primary of the OUTPUT 1 CONTROL SCR DIODE HYBRID BRIDGE ARC FORCE SELECTOR I FEEDBACK NEGATIVE OUTPUT TERMINAL OPTIONAL l POLARITY 1 l switch SHUNT POSITIVE QUT TERMINAL control transformer secondary of the control transformer supplies 120VAC power via the power switch and thermostats to activate the input contac tor A reconnect panel allows the user to configure the machine for the desired input voltage This AC input voltage is applied to the primary of the main trans former The transformer changes the high voltage low current input power to a lower voltage higher current output The finishes or neutrals of the main secondary coils are connected together and the three starts of the secondary windings are connected to the rectifier bridge assembly addition three 66VAC phase angle windings are housed in the main transformer assembly These windings provide power and timing for the control board Two of these coils provide 120VAC for the fan motor NOTE Unsh
130. tom iron 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 36 for proper positioning 4 Place insulation Lincoln Electric part number 520728 on top of each of the three primary coils The longer side of the insulation should be placed toward the front of the machine See Figure 7 for the location of this insulation 5 Place the three secondary coils on top of the insu lation installed in Step 4 The leads should come out at the front of the machine with the short leads on top See F 36 for proper positioning 6 Insert shims Lincoln Electric part number 001250 or 000317 between the secondary coil sides and the iron assembly on either side of the legs See Figure F 37 PRIMARY COIL LEADS 7 Place insulation Lincoln Electric part number 520728 on top of each of the three secondary coils The longer side of the insulation should be placed toward the front of the machine where the secondary start and finish leads come out See Figure 37 8 Install the three top primary coils noting which is right left and center Leads should come out at the back of the machine See Figure F 29 tor prop er positioning The coils must be in correct position left center right 9 Install the top iron lamination and choke assem With the 9 16 deep well socket wrench reassemble the four thru bolt
131. trical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in the removal and replacement of the SCR diode assembly Return to Section TOC Return to Master TOC MATERIALS NEEDED 5 16 Nut driver 7 16 Wrench 1 2 Wrench 9 16 Wrench 3 8 Wrench Slot head screw driver 1 2 Socket and extension 7 2 This procedure takes approximately 35 minutes to perform 8 E Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC HE 8 E Return to Section TOC Return to Master TOC 7 2 44 GLASTIC STIFFENERS F 44 TROUBLESHOOTING amp REPAIR SCR DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT continued FIGURE F 27 SCR DIODE ASSEMBLY DETAILS MOUNTING BRACKETS PROCEDURE 1 Remove the main input supply power to the machine With the 5 16 nut driver remove the case top and sides Lower the front control panel Using the 5 16 wrench remove the six screws mounting the front assembly to the machine s base Carefully inch the fron
132. ut driver remove the case top and sides Remove the two fiber baffles from the left and right sides of the choke See Figure F 33 If the optional Pocket Amptrol diodes are installed label and disconnect the neces sary leads for removal of the lift bail One lead is on the shunt and one lead is on the optional polarity switch Label and cut leads 218 and 219 from the sensing resistor See the Wiring Diagram These leads will have to be resoldered upon reassembly Remove resistor R3 40 ohms 100 watts LIFT BAIL POCKET AMTROL DIODE gt SENSING RESISTOR BAIL TRANSFORMER 45 IRON MOUNTING BOLTS 4 6 Using the 9 16 socket wrench remove the four bolts left and right mounting the lift bail to the transformer top and bottom irons 7 Using the 9 16 socket wrench remove the four bolts flat washers and lock washers mounting the lift bail assembly to the base of the machine WARNING The transformer and choke assembly is now loose and free to slide or tip on the base of the machine 8 Remove the lift bail by lifting straight up and clear from the machine Clear any remaining leads necessary for lift bail removal IDEALARC R3R LINCOLN F 56 F 56 TROUBLESHOOTING amp REPAIR MAIN TRANSFORMER REMOVAL amp REPLACEMENT continued FIGURE 34 CHOKE REMOVAL Return to Section TOC Return to Master TOC CHOKE THRU BOLTS
133. y Note that each vertical division represents 2 volts and that each horizontal division represents 5 milliseconds in time Note Scope probes connected at SCR gate and cathode probe to gate and cathode probe to gate probe to cathode R3R 500 machine O10 515 0 gt 1 SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling ctis DC WWAQ Internal Return to Section TOC Return to Master TOC IDEALARC R3R LINCOLN F 38 F 38 TROUBLESHOOTING amp REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING Return to Section TOC Return to Master TOC O volts Return to Section TOC Return to Master TOC 50 volts 5 ms This is NOT the typical DC output voltage waveform One output SCR is not functioning Note the in the waveform One SCR gate is dis connected to simulate an open or non functioning output SCR Each vertical division represents 50 volts and each horizontal division repre sents 5 milliseconds in time The machine was loaded with a resis tance grid bank Note Scope probes connected at machine output terminals 4 probe to positive terminal probe to neg ative terminal R3R 500 machine O10 515 0 gt 1

Lincoln Electric IDEALARC R3R-500 User's Manual

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