Lincoln Electric 11289 Operator'S Manual Download Page 7

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TABLE OF CONTENTS

Page

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Technical Specifications  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Input Power Connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Duty Cycle  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Output Connections  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

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Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

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Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C

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Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D

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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-7 – E-10

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Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

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Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-527 Series

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Summary of Contents for 11289

Page 1: ...e ex 10859 Serial ex U1060512345 IM885 A Issue D ate 6 Nov Lincoln Global Inc All Rights Reserved For use with machines having Code Numbers 11289 11343 Register your machine www lincolnelectric com register Authorized Service and Distributor Locator www lincolnelectric com locator ...

Page 2: ...ER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding 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 avail...

Page 3: ...er for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produc...

Page 4: ...event 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...ppropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier ...

Page 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Page 7: ...________________________________________________________________________________________ Maintenance Section D __________________________________________________________________________________________ Troubleshooting Section E Troubleshooting Procedures E 7 E 10 __________________________________________________________________________________________ Wiring Diagram Section F ____________________...

Page 8: ...30V 50 60Hz 380 400V 50 60Hz 440 460V 50 60Hz 11 3 220V 50Hz 74 500A Rated Input Current 103A 600A Output 92A 500A Output 68A 375A Output 220V 50 60Hz Volts Hz DC RATED OUTPUT PHYSICAL DIMENSIONS HEIGHT 27 5 in 699 mm WIDTH 22 3 in 566 mm DEPTH 32 0 in 813 mm WEIGHT 446 lbs 203 kg Current Range 75 625 Amps Maximum Open Circuit Voltage 64VDC TEMPERATURE RANGES POWER FACTOR RATED LOAD IDLE CURRENT O...

Page 9: ...e phase input power to the three line terminals on the input contactor and the earth ground lead to the ground stud marked with the symbol Install the reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover DUTY CYCLE The maximum output rating of this welder is at a 35 duty cycle Duty cycle is based on a ten minute period Therefore the welder can be operat...

Page 10: ...ent control dial labeled I on the front of the machine indicates the output current On the R3R 375 I there is only one dial On the R3R 500 I and 600 I there are two dials The A range controls the current over about 1 2 of the B range A toggle switch on the control panel allows selection of the desired range The output control can be adjusted while welding MACHINE OR REMOTE CURRENT CONTROL SWITCH P...

Page 11: ... REMOTE SWITCH Remote Output Current Control F POLARITY SWITCH Factory installed option on domestic models only Electrode Polarity Positive Electrode Polarity Negative Do Not Switch While Welding G RATING PLATE Three Phase Power Transformer Rectifier Rectified DC Output Constant Current Characteristics Shielded Metal Arc Welding Line Connection H HIGH TEMPERATURE WARNING LIGHT High Temperature Lim...

Page 12: ...me care must be observed when installing or extending the wiring of a remote control The Remote Control cord can be lengthened to any length by splicing four wires to the standard 28 ft 8 5 m cord before connecting to the R3R recep tacle Only the green lead can and should be grounded to the machine case K841 UNDERCARRIAGE For easy moving of the machine platform undercar riage with mounting two gas...

Page 13: ...ntenance required The probe tip should be kept in condition to provide sharp edges at the ends to assure penetration of heavy oxide coatings on the work piece A blunted tip could result in giving different welding currents for a given dial setting POWER RECTIFIER REPLACEMENT Refer to the troubleshooting section Power Rectifier Bridge Assembly Checking Procedure if a rectifier fail ure is suspected...

Page 14: ...that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Tra...

Page 15: ...put contactor coil open 7 Open winding on 115V pilot transformer 8 Power ON OFF switch not closing 9 Lead broken or loose connec tion in 115V starter circuit 10 Thermostats defective High Temperature Warning Light should be lit 1 Repair or replace 2 Check with Power Company 1 Replace look for reason for blown fuse first 2 Check voltage 3 Repair 4 Check voltage against instructions 5 a Make sure th...

Page 16: ...ode or work lead loose or broken 2 Open transformer primary or secondary circuit 3 Supply line fuse blown 4 Input line grounded causing single phase input 5 Input leads not connected to contactor 6 Latching resistor R3 open 7 Control circuit problems 1 Possible defective power SCR 2 Possible defective control board 1 Repair connections 2 Repair 3 Replace blown fuse check fuse size 4 Repair input t...

Page 17: ...eshooting Section E 1 Input fuse blown Machine is single phased 2 One phase of main transformer windings open 3 Defective power bridge 1 Improper ventilation 2 Loaded beyond rating 3 Fan inoperative 4 Shorted diode or SCR in power rectifier bridge 1 Excessive load causing the over load protection on control board to operate 2 Machine output shorted causing overload protection on control board to o...

Page 18: ...e 1 Poor work or electrode cable connection 2 Current too low 3 Welding leads too small 4 Open SCR or diode in power rectifier bridge 5 Control circuit problems 1 Input contactor contacts frozen 1 Current control switch in wrong position 2 Current control switch defective 3 Current control potentiometer defective 4 Lead or connection in control circuit open 5 Defective control or circuit boards 1 ...

Page 19: ...E OF ACTION L Optional remote current control not functioning See Troubleshooting Section C before connecting 1 Current control switch in the wrong position 2 Leads 75 76 and 77 not con nected to correct numbers on models with terminal strip 3 Remote control leads broken 4 Remote control potentiometer open 5 Lead or connection in current control circuit open 6 Control PC board plug discon nected o...

Page 20: ...replacing check repair are OK one at a time changes OCV each gate lead one at a time does NOT change OCV Codes below 9500 with power off remove leads from Identify gate lead that when Codes above 9500 75 76 77 terminal strip and removed OCV did not change with power off disconnect welding leads from output terminals Remove gate lead Voltage remote control amphenol between gate lead and 204 must be...

Page 21: ...cuit Only the green lead can and should be grounded to the machine case When extending the standard remote control make sure the leads are the same and the splice is waterproof Be very careful not to ground the cable when in use and do not let these connections touch against the case D OUTPUT VOLTAGE The open circuit voltage of the machine should be 66 to 71 volts and should not vary when the rheo...

Page 22: ...ther step 3 or step 4 fails replace the switch I REMOTE CONTROL CHECK For codes above 9500 the remote control Amphenol pin assignments are pin C 75 pin B 76 and pin A 77 Disconnect the remote field control and connect an ohmmeter across 75 and 76 and rotate the rheostat in the remote control The resis tance reading should go from zero to 10K ohms Repeat with triplet across 77 and 76 with same resu...

Page 23: ...Step b and a much higher resistance in Step c K POWER SILICON CONTROLLED REC TIFIER TEST The SCR must be mounted in the heat sink when making this test a Connect the ohmmeter set to the X10 scale leads to the anode and cathode b Reverse the leads of the ohmmeter from Step a c A shorted SCR will indicate zero or an equally low resistance in one or both directions d Establish the polarity of the ohm...

Page 24: ... 5 6 66V BOTTOM PRIMARY TOP PRIMARY T1 X1 X2 X3 SEC SEC SEC 16 17 18 ARE PRESENT ON 380 500 OR 460 575 MACHINES ONLY THERE IS NO 10 11 12 CONNECTION ON 380 A CHOKE THERMOSTAT SECONDARY THERMOSTAT 233 231 204 ICR 1 2 3 L1 L2 L3 RECONNECT PANEL SHOWN CONNECTED FOR 220V H4 234 235 FAN MOTOR HIGH TEMP LIGHT 221 222 223 G1 G2 G3 204 G1 G2 G3 204 226 220 204 211 210 213 77 212 76 SW3 A AMBER G GREEN W W...

Page 25: ...F 2 DIMENSION PRINT IDEALARC R3R 600 I F 2 R3R 600 I K817 or K817R K841 not shown Part No Type A B C D F G H M12244 7 R3R 32 00 15 39 3092 1 44 30 02 11 33 07 06 94 M12244 7 7 7 78 ...

Page 26: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 27: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 28: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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