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Section B-1

Section B-1

IDEALARC R3R

TABLE OF CONTENTS

- OPERATION SECTION -

Operation

...............................................................................................................................

Section B

Safety Instructions ......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes ...................................................................................................B-3

Design Features and Advantages ........................................................................................B-3

Welding Capability................................................................................................................B-3

Controls and Settings  ................................................................................................................B-4

Welding Operation ......................................................................................................................B-6

Operating Steps ...................................................................................................................B-6

Local Control..................................................................................................................B-6

Remote Control ..............................................................................................................B-6

Pocket Amptrol ..............................................................................................................B-6

Summary of Contents for IDEALARC R3R-300

Page 1: ...T And most importantly think before you act and be careful SERVICE MANUAL World s Leader in Welding and Cutting Products 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 For use with machine code numbers 9534 9537 9874 and 9884 IDEALARC R3R 300 400 and 500 Return to Master...

Page 2: ...E SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER 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 F...

Page 3: ...round the work or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be th...

Page 4: ...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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent h...

Page 5: ...oudage à l aide d écrans appropriés et non inflamma bles 4 Des gouttes de laiter en fusion sont émises de l arc de soudage Se protéger avec es 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 ...

Page 6: ...fety Instructions B 2 General Description B 3 Controls and Settings B 4 Welding Operation B 6 Accessories Section C Maintenance Section D Safety Precautions D 2 Routine and Periodic Maintenance D 2 General Component Locations D 3 Theory of Operation Section E Troubleshooting and Repair Section F How To Use Troubleshooting Guide F 2 Troubleshooting Guide F 4 Test Procedures F 10 Oscilloscope Wavefo...

Page 7: ...l Specifications Idealarc R3R 300 A 2 Technical Specifications Idealarc R3R 400 A 3 Technical Specifications Idealarc R3R 500 A 4 Safety Precautions A 5 Select Suitable Location A 5 Lifting A 5 Tilting A 5 Stacking A 5 Input Connections A 6 Ground Connection A 6 Input Supply Connections A 6 Input Wire and Fuse Size A 7 Reconnect Procedure A 8 Output Connections Stick TIG Air Carbon Arc A 9 ...

Page 8: ... Rated Amps 100 230 29 60 300 32 35 375 35 OUTPUT Current Range Maximum Open Circuit Voltage 45 to 375 Amps 67 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES AT 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...

Page 9: ... Rated Amps 100 300 32 60 400 36 35 500 40 OUTPUT Current Range Maximum Open Circuit Voltage 60 to 500 Amps 67 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES AT 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...

Page 10: ... Rated Amps 100 600 44 60 500 40 35 375 35 OUTPUT Current Range Maximum Open Circuit Voltage 75 to 625 Amps 67 VDC RECOMMENDED INPUT WIRE AND FUSE SIZES AT 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...

Page 11: ...t 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 R3R weights are as follows R3R 300 350 pounds 159 kilograms R3R 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...

Page 12: ...le 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 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 pow...

Page 13: ...n the Technical Specifications page Choose an input and grounding wire size according to local or national codes also see the appropriate Technical Specifications page Using fuses or circuit breakers smaller than recommended may result in nuisance shut offs from welder inrush currents even if you are not welding at high currents INSTALLATION A 7 A 7 IDEALARC R3R Return to Section TOC Return to Sec...

Page 14: ... TAPE TO PROVIDE AT 3 CONNECT L1 L2 L3 INPUT SUPPLY LINES AND H2 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN 3 CONNECT L1 L2 L3 INPUT SUPPLY LINES AND H3 TRANSFORMER LEADS TO THE INPUT SIDE OF THE CR1 CONTACTOR AS SHOWN INPUT SUPPLY CONNECTION DIAGRAM Do not touch electrically live parts Only qualified persons should install use or service this equipment removed servicing Do ...

Page 15: ...all times INSTALLATION A 9 A 9 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE A 4 OUTPUT TERMINAL CONNECTIONS 1 2 3 1 NEGATIVE WELDING CABLE CONNECTION 2 POSITIVE WELDING CABLE CONNECTION 3 CABLE STRAIN RELIEF HOLES OUTPUT CONNECTIONS STICK TIG AIR CARBON...

Page 16: ...NOTES A 10 A 10 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 17: ...C R3R TABLE OF CONTENTS OPERATION SECTION Operation Section B Safety Instructions B 2 General Description B 3 Recommended Processes B 3 Design Features and Advantages B 3 Welding Capability B 3 Controls and Settings B 4 Welding Operation B 6 Operating Steps B 6 Local Control B 6 Remote Control B 6 Pocket Amptrol B 6 ...

Page 18: ...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 dangerous 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...

Page 19: ...needs no maintenance Fully recessed control panel protects controls and minimizes accidental contact Recessed output terminals reduces chance of acci dental contact Low 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 machi...

Page 20: ... minimum 4 CURRENT RANGE SELECTOR SWITCH R3R 400 and R3R 500 only A position selects lower range current control B position selects higher range current control 5 OUTPUT CONTROL SWITCH R3R OR REMOTE POSITIONS Selects the mode of control In the R3R position control is by the machine control panel In the Remote position control is through an optional remote control device 6 OUTPUT CONTROL POTENTIOME...

Page 21: ...ITY SWITCH optional Permits chang ing the electrode polarity of the output terminals between DC 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 ...

Page 22: ...he 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 ran...

Page 23: ...Meters C 2 Pocket Amptrol C 2 Field Installed Options C 2 Remote Output Adapter Cable K857 C 2 Accessory Kits K703 K704 C 2 Undercarriages K817P K841 C 2 TIG Welding Options C 2 TIG Module K930 1 C 2 Water Valve Kit K844 1 C 2 Amptrols K870 K812 K963 1 K963 2 C 2 Contactor Kit K938 1 C 2 Docking Kit K939 1 C 2 Control Cable K936 3 C 2 Control Cable Extensions K937 22 5 K937 45 C 2 Section C 1 Sect...

Page 24: ...ncy 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 Co...

Page 25: ...er TOC Return to Master TOC Return to Master TOC Section D 1 Section D 1 IDEALARC R3R TABLE OF CONTENTS MAINTENANCE SECTION Maintenance Section D Safety Precautions D 2 Routine and Periodic Maintenance D 2 General Component Locations D 3 ...

Page 26: ...e 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 s...

Page 27: ...3 D 3 IDEALARC R3R 11 12 10 9 8 7 6 5 4 3 2 1 13 FIGURE D 1 GENERAL COMPONENT LOCATIONS 1 CONTROL PANEL 2 SCR DIODE BRIDGE 3 MAIN TRANSFORMER 4 CHOKE 5 RECONNECT PANEL LOCATION 6 INPUT CONTACTOR LOCATION 7 FAN ASSEMBLY 8 CONTROL TRANSFORMER LOCATION 9 PC BOARDS LOCATION 10 CASE FRONT 11 OUPUT TERMINALS LOCATION BENEATH HINGED PANEL 12 POCKET AMPTROL OPTIONAL 13 POLARITY SWITCH OPTIONAL ...

Page 28: ...NOTES D 4 D 4 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 29: ...ircuits E 4 Protective Devices and Circuits E 5 SCR Operation E 6 CONTROL BOARD OUTPUT CONTROL ARC FORCE CONTROL CONTROL TRANSFORMER POWER SWITCH R E C O N N E C T INPUT CONTACTOR TRANSFORMER MAIN SCR DIODE HYBRID BRIDGE SHUNT OUTPUT CHOKE NEGATIVE OUTPUT TERMINAL POSITIVE OUTPUT TERMINAL G A T E S I G N A L S FEEDBACK F E E D B A C K THERMOSTATS FAN MOTOR TERMINAL STRIP REMOTE SWITCH DIAL SELECTO...

Page 30: ...rrent 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 In 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 THEORY OF OPER...

Page 31: ...e negative output terminal stores energy and provides current filtering for the constant current welding arc THEORY OF OPERATION E 3 E 3 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTE Unshaded areas of Block Logic Diagram are the subject of discussion FIGUR...

Page 32: ...CH DIAL SELECTOR SWITCH SNUBBER BOARD AMPHENOL POLARITY SWITCH OPTIONAL OPTIONAL POCKET AMPTROL PC BOARD OPTIONAL POCKET AMPTROL TRANSFORMER OPTIONAL POLARITY SWITCH AND POCKET AMPTROL CIRCUITS The polarity switch permits changing the arc polarity at the output terminals of the R3R machine This switch should not be changed while welding The Pocket Amptrol option provides the operator with wireless...

Page 33: ...ved 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...

Page 34: ...An SCR is fired by 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 0 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...

Page 35: ...t Test F 31 Oscilloscope Waveforms F 35 Normal Open Circuit Voltage Waveform Maximum Output No Load F 35 Typical Output Voltage Waveform Machine Loaded F 36 Typical SCR Gate Voltage Waveform Maximum Output No Load F 37 Abnormal Open Circuit Voltage Waveform One Output SCR Not Functioning F 38 Replacement Procedures F 39 Input Contactor CR1 Cleaning Replacement F 39 Fan Motor and Blade Removal and ...

Page 36: ...ENT 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 ap...

Page 37: ...h which could have a static charge If the PC Board can t be installed immediately put it back in the static shielding bag If the PC Board uses protective shorting jumpers don t remove them until installation is complete If 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...

Page 38: ...ice Department 216 383 2531 or 1 800 833 9353 WELD Machine is dead no output no fan no pilot light 1 Make sure that the input power switch is in the ON position 2 Check the three phase input voltage at the machine Input voltage must match the rating plate and the reconnect panel 3 Check for blown or missing fuses in the input lines 1 Check the input power switch S1 for proper operation See the Wir...

Page 39: ...e for proper cir culation of air Operate the machine at rated current and duty cycle 1 Check the leads and connec tions between the thermostats the input contactor 1CR and the power switch SW1 See the Wiring Diagram 2 One of the normally closed thermostats may be faulty The input contactor CR1 chatters 1 Make certain the three phase input voltage matches the rat ing plate and the reconnect panel 1...

Page 40: ...f 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 4 Make sure the remote control leads 75 76 77 are not grounded or shorted to the positive or negative welding output 1 Check the Output Control R1 and associated wiring See the Wiring Diagram 2 Check the Output Control Switch S2 and...

Page 41: ...t on R3R 300 3 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 1 Check the Output Control R1 Normal resistance is...

Page 42: ...are always electrically hot 1 This is a normal condition The open circuit voltage should be approximately 67VDC The open circuit voltage may vary with the input line voltage The machine welds but reduces to a low output under load and remains there until the load is removed and the arc re started 1 Operating the machine beyond the current rating will cause the overload protection circuit on the co...

Page 43: ...S RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Poor arc characteristics 1 Make sure the correct weld pro cedures are being used Electrode Polarity etc 2 Check the welding cables for loose or faulty connections 1 Perform the SCR Diode Rectifier Bridge Test 2 Perform the Main Transformer Test 3 The control board may be faulty Replace The welding arc is variable and sluggish 1 Check the input voltag...

Page 44: ...r 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...

Page 45: ...ct an AC voltmeter to the leads Electric Shock can kill With the input power on there are high voltages inside the machine Do not reach into the machine or touch any internal part of the machine while the power is on 5 Apply the correct voltage to the machine and turn the power switch S1 ON 6 Check for 120VAC at the contactor coil leads If the 120VAC is NOT present with the power switch S1 on chec...

Page 46: ...ly 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 4 With the contactor activated check the con tinuity across the contacts Zero ohms or very low resistance is normal See Figure F 2 If the resistance is high the input con tactor is faulty Replace the input contactor 5 When the contactor is NOT activa...

Page 47: ...r 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...

Page 48: ...t reach into the machine or touch any internal part of the machine while the power is on 5 Apply the correct voltage to the machine and turn the power switch S1 ON 6 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 pre...

Page 49: ...VDC 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 4 With the contactor activated check the con tinuity across the contacts Zero ohms or very low resistance is normal See Figure F 4 If the resistance is high the input con tactor is faulty Replace 5 When the contactor is NOT activated the resistance should ...

Page 50: ...lectrical 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 ...

Page 51: ...t control panel 3 Locate the control transformer T2 on the left side of the input box facing the back of the machine See Figure F 5 4 Locate the control transformer primary leads H1 H2 H3 etc See the Wiring Diagram NOTE Unused leads should be taped a Inspect for broken or incorrect con nections 5 Locate control transformer leads X1 top and X2 a Lead X1 is connected to the input con tactor CR1 coil...

Page 52: ... nor the meter probe touches any metal surfaces c Connect the other meter probe to the 231 connection at the power switch See Figure F 6 d Apply input power to the R3R 7 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 8 If 115VAC is not present between leads X1 and 231 check the spliced connection between 231...

Page 53: ... 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 voltage...

Page 54: ...ides and the reconnect panel cover 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 5...

Page 55: ...If the proper voltage is present for all three phases the input contactor is working properly b If the 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 11 Test with an AC voltmeter for approximate ly 50VAC across each of the three main secondary start leads located at the SCR Diode Rectifier Bridge Remove the r...

Page 56: ...2206 see Figure F 9 for lead locations For control board G1575 see Figure F 10 for lead locations NOTE If the main input supply voltage varies the main transformer voltages will vary proportionately a If the voltage is low remove the plug or leads and recheck the voltage for 66VAC If the reading is normal the control board may be faulty Replace the control board b If one or more of the voltage tes...

Page 57: ...TROUBLESHOOTING REPAIR F 23 F 23 IDEALARC R3R 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 MAIN TRANSFORMER T1 VOLTAGE TEST continued FIGURE F 9 CONTROL BOARD G2206 TEST POINTS FIGURE F 10 CONTROL BOARD G1575 TEST POINTS R3R CONTROL G2206 R3R CONTROL G1575 Plug P3 201 202 203 204 201 202 203 204 Plug P4 ...

Page 58: ...oid 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 determi...

Page 59: ...the welding output terminals 4 Disconnect molex plug P4 from control board G2206 See Figure F 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 5 Locate and remove molex plug P5 from snubber board M15370 See Figure F 13 If the machine has snubber board M14215 label and disconnect Lead 204 from the out put shunt Be sure to dis...

Page 60: ...eturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FIGURE F 14 RESISTOR R3 LOCATION FIGURE F 13 SNUBBER BOARD M15370 PLUG P5 LOCATION RESISTOR R3 STATIC SCR DIODE RECTIFIER BRIDGE TEST continued M15370 SNUBBER Plug P5 ...

Page 61: ...Test the resistance of SCR 2 and SCR 3 using the same procedure described in Step 8 10 Measure the resistance of diode D1 from anode probe to cathode probe using an analog ohmmeter set at R x 1000 scale The resistance should be low See Figure F 15 a Reverse the meter leads and measure the resistance from cathode probe to anode probe of diode D1 The resistance should be high See Figure F 15 b If a ...

Page 62: ... 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 he...

Page 63: ... 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 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...

Page 64: ...meter for zero voltage a If the voltage reading is higher than zero the SCR is shorted 13 Close or keep closed switch SW 1 14 Close switch SW 2 for 2 seconds Release and read meter a If the 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 clos...

Page 65: ... 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 9...

Page 66: ...s equipped with a polari ty switch the switch handle will have to be removed using a 1 8 Allen type wrench Electric Shock can kill With the input power on there are high voltages inside the machine Do not reach into the machine or touch any internal part of the machine while the power is on 4 Apply the correct input power to the machine 5 Check the T3 primary voltage at leads 201A to 203A See Figu...

Page 67: ... 22 a With the Pocket Amptrol in position 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 an...

Page 68: ...L CIRCUIT TEST continued FIGURE F 23 SENSING RESISTOR R4 R4 SENSING RESISTOR FIGURE F 24 POCKET AMPTROL SIMPLIFIED DRAWING POCKET AMPTROL P C BOARD CONTROL P C BOARD SCR DIODE RECTIFIER BRIDGE 1J7 2J7 3J7 GREEN YELLOW GREEN 201A 203A 1J6 2J6 218 219 R4 0 4 OHMS MACHINE REMOTE SWITCH 77 76 5J6 4J6 3J6 75 5J1 SHUNT POSITIVE OUTPUT TERMINAL NEGATIVE OUTPUT TERMINAL CHOKE POCKET AMPTROL SENSING ASSEMB...

Page 69: ... 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 SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUI...

Page 70: ...achine 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 SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Di...

Page 71: ...as in an open circuit condition no load and operating properly 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 SCOPE SETTINGS Volts Div 2V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal TYPIC...

Page 72: ... 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 probe to positive terminal probe to neg ative terminal R3R 500 machine SCOPE SETTINGS Volts Div 50V Div Hori...

Page 73: ...ctrical 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 t...

Page 74: ...e the input contactor assembly 6 Replace the input contactor cover plate CONTACTOR REPLACEMENT PROCEDURE 1 Disconnect main input supply power to the machine 2 Locate and get access to the input contac tor CR1 in the input box See Figure F 25 3 Disconnect the main input supply power leads L1 L2 and L3 to the input contactor Remove the control transformer primary leads H1 H2 or H3 dependent on input...

Page 75: ...alidate 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 electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 ...

Page 76: ...e machine case back to gain clearance to remove the fan See Figure F 26 4 If 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 5 Remove the four mounting nuts and associ ated flat and lock washers that hold the motor to the mounting bracket See Figure F 26 6 Carefully remove the fan motor 7 To replace the fan motor...

Page 77: ...actory 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 electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 W...

Page 78: ...ge assembly 4 Remove the two screws holding the air deflector R3R 500 only to the front panel Remove the air deflector 5 Remove the glastic stiffeners one on each side left and right See Figure F 27 6 Remove the choke from the left side of the negative heat sink plate See Figure F 27 7 Remove the two 220 leads from the right side of the negative heat sink plate 8 Remove the positive lead and shunt...

Page 79: ...ch 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 F 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 F 27 22 Check all lead placements and secure 23 Attach the front assembly to the machin...

Page 80: ...ety 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 ...

Page 81: ...ess 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 4 Alternately loosen nuts 1 2 turn each until heat sinks are loose Remove nuts and leaf spring IT IS RECOMMENDED THAT NEW HARDWARE LEAF SPRING AND HOUSING BE USED FOR REASSEMBLY 5 Remove the old SCR 6 Clean the area on the heat sin...

Page 82: ...ide 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 A 1 4 28 thread requires a different tightening procedure than a 1 4 20 thread PROCEDURE FOR THE 1 2 INCH WIDE SPRING 1 Place a piece of sleeving around each cap screw 2 Insert cap screws through the leaf spring Orient the leaf sp...

Page 83: ...first cap screw 1 4 turn 3 Tighten second cap screw 1 2 turn 4 Tighten first cap screw 1 2 turn 5 Tighten second cap screw 1 2 turn 6 Tighten first cap screw 1 4 turn Stop 7 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 ...

Page 84: ... 1 8 inch wide standoff facing up See Figure F 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 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 t...

Page 85: ...w 1 2 turn 7 Tighten second cap screw 1 4 turn STOP 8 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 t...

Page 86: ...our 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 fol...

Page 87: ...not use steel wool or any abrasive cleanser on the diode mounting surface 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 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 wren...

Page 88: ... 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 electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid ...

Page 89: ...ensing resistor See the Wiring Diagram These leads will have to be resoldered upon reassembly 5 Remove resistor R3 40 ohms 100 watts 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 ma...

Page 90: ...nal 3 Remove the bottom choke lead from the neg ative rectifier plate 4 Label and cut the choke thermostat leads 5 Using the 9 16 deep well socket wrench 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 6 Using a hoist carefully lift the choke and top iron assembly out and clear of the trans former coils NOTE ...

Page 91: ...LS 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 th...

Page 92: ...ils 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 F 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 for prop er positioning The coils must be in correct position left center right 9 Install the top iron l...

Page 93: ...urn to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING REPAIR F 59 F 59 IDEALARC R3R MAIN TRANSFORMER REMOVAL REPLACEMENT continued 10 If necessary trim off excess secondary lead stickout and TIG weld the leads together See Figure F 38 FIGURE F 38 SECONDARY LEAD TRIM AND WELD DETAIL TIG WELD ...

Page 94: ...with four bolts flat washers and lock washers 2 Using the 9 16 socket wrench attach the lift bail to the transformer top and bottom irons with four bolts 3 Install resistor R3 40 ohms 100 watts 4 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 le...

Page 95: ... INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 8 1 0 92 208 3 60 7 8 0 92 230 3 60 7 0 0 92 400 3 60 4 0 0 92 440 3 60 3 7 0 92 460 3 60 3 5 0 92 480 3 60 3 4 0 92 575 3 60 2 8 0 92 200 3 50 14 4 1 0 220 3 50 13 0 1 0 380 3 50 7 5 1 0 400 3 50 7 2 1 0 415 3 50 6 9 1 0 425 3 50 6 7 1 0 440 3 50 6 5 1 0 500 3 50 5 7 1 0 550 3 50 5 2 1 0 OPEN CIRCUIT VOL...

Page 96: ...T IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 9 5 1 04 208 3 60 9 2 1 04 230 3 60 8 3 1 04 380 3 60 5 0 1 04 440 3 60 4 3 1 04 460 3 60 4 1 1 04 550 3 60 3 4 1 04 575 3 60 3 3 1 04 200 3 50 18 6 1 15 220 3 50 17 0 1 15 230 3 50 16 3 1 15 380 3 50 9 8 1 15 400 3 50 9 3 1 15 415 3 50 9 0 1 15 440 3 50 8 5 1 15 500 3 50 7 5 1 15 550 3 50 6 8 1 15 OPEN CIRCUI...

Page 97: ...ts INPUT IDLE AMPS AND WATTS Input Volts Phase Hertz Maximum Idle Amps Maximum Idle KW 200 3 60 10 9 1 2 208 3 60 10 5 1 2 230 3 60 9 5 1 2 415 3 60 5 3 1 2 440 3 60 5 0 1 2 460 3 60 4 8 1 2 550 3 60 4 0 1 2 575 3 60 3 8 1 2 200 3 50 19 8 1 2 220 3 50 18 0 1 2 230 3 50 17 2 1 2 380 3 50 10 4 1 2 400 3 50 9 9 1 2 415 3 50 9 5 1 2 440 3 50 9 0 1 2 500 3 50 7 9 1 2 550 3 50 7 2 1 2 OPEN CIRCUIT VOLTA...

Page 98: ...NOTES F 64 F 64 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 99: ... Master TOC Return to Master TOC TABLE OF CONTENTS ELECTRICAL DIAGRAMS SECTION Electrical Diagrams Section G Wiring Diagram R3R 300 G 3 Wiring Diagram R3R 400 Code 9537 G 4 Wiring Diagram R3R 400 Code 9874 R3R 500 G 5 Pocket Amptrol Schematic G 6 Snubber Board Schematic Layout G 7 R3R 300 Control PC Board G 8 R3R 400 Control PC Board G 9 R3R 500 Control PC Board G 10 ...

Page 100: ...NOTES G 2 G 2 IDEALARC R3R Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Page 101: ...8 7 6 5 4 RECONNECT PANEL SHOWN CONNECTED FOR 380V TO PRIMARY COILS H4 234 235 FAN MOTOR 221 222 223 G1 G2 G3 204 G1 G2 G3 204 226 220 204 211 210 213 77 212 76 SWITCH SHOWN IN LOCAL POSITION A AMBER G GREEN W WHITE Y YELLOW COLORS 235 232 ARE MADE AT THE SINGLE 346V AND ABOVE EXCEPT 380V 380V OR TRIPLE VOLTAGE SINGLE BELOW 346V OR DUAL VOLTAGE 380 500 OR 460 575 V 66V 66V 76 77 SW4 OPTIONAL POLAR...

Page 102: ...IMARY T1 X1 X2 X3 SEC SEC SEC 13 14 15 ARE PRESENT ON 380 500 OR 460 575 MACHINES ONLY THERE IS NO 10 11 12 CONNECTION ON 380 OR TRIPLE VOLTAGE MACHINES A CHOKE THERMOSTAT SECONDARY THERMOSTAT 233 231 204 ICR 1 2 3 L1 L2 L3 11 10 12 3 2 1 9 8 7 6 5 4 RECONNECT PANEL SHOWN CONNECTED FOR 380V TO PRIMARY COILS TO PRIMARY COILS H4 234 235 FAN MOTOR HIGH TEMP LIGHT 221 222 223 G1 G2 G3 204 G1 G2 G3 204...

Page 103: ...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 11 10 12 3 2 1 9 8 7 6 5 4 RECONNECT PANEL SHOWN CONNECTED FOR 380V 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 A M B E R G G R E E N W W H I T E Y Y E L L O W C O L O R S 235 232 ARE MADE AT THE SINGLE 346V AND AB...

Page 104: ...GREE ON 3 PLACE DECIMALS IS OO2 ON HOLES SIZES PER E 2056 10 25V C18 C21 ChÕge Sht No UNLESS OTHERWISE SPECIFIED TOLERANCE WITH PUBLISHED STANDARDS 12V FRAME CONNECTION CANADA FRANCE AUSTRALIA C H K L R3R POCKET AMPTROL B 10K CW R7 47 5K R33 Q2 A 1 2W 82 R 5 C 75 77 NUMBER N A SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE NOTES WITHOUT AFFECTING THE INTERCHANGEABILITY OF A CO...

Page 105: ...J 130V TP2 3 8 J 130V TP1 400V 68 C1 5 W 10 R1 400V 68 C3 221 2 2 2 223 2 0 4 J 5 5 J 5 1 8 0 J 150V TP6 160J 320V TP5 160J 320V TP4 600V 05 C 4 600V 05 C 5 J 5 7 2 2 4 2 2 0 2 2 5 GENERAL INFORMATION 3 8 9 1 G 1 2 2 0 9 6 F G 7 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Page 106: ...753 R42 R59 R60 R61 4 R44 R86 R87 R88 4 S16668 3 100pF 100 C O M M O N 1 0 V C B J L K N D M E F G A H R 3 R 3 0 0 C O N T R O L G 2 1 7 3 1 R 1 R 2 R 3 R 8 8 R 6 1 R 7 0 R 7 3 R 7 6 R 8 5 R 8 2 R 8 7 R 8 6 R 6 0 R 5 9 R 6 9 R 6 8 R 7 2 R 7 1 R 7 5 R 7 4 R 8 4 R 8 3 R 7 8 R 7 7 R 7 9 R 8 1 R 8 0 R 3 3 R 3 2 R 4 2 R 3 5 R 5 0 R 4 8 R 3 7 R 4 0 R 3 8 R 4 5 R 4 1 R 2 7 R 5 4 R 4 7 R 1 5 R 2 8 R 1 2 R...

Page 107: ...3640 12 S15128 9 S15128 4 10M 1 2W S19400 3321 68 5W 38J 15V COMMON 10V C B J L K N D M E F G A H R 3 R 2 R 1 R 8 9 R 1 8 R 1 0 0 R 1 0 1 R 1 0 3 R 1 0 2 R 2 6 R 9 9 R 9 8 R 2 5 R 4 4 R 3 9 R 2 1 R 5 5 R 2 2 R 2 4 R 1 7 R 1 9 R 2 0 R 1 1 R 1 4 R 1 3 R 5 3 R 1 2 R 2 8 R 1 5 R 3 6 R 4 7 R 5 4 R 2 7 R 4 1 R 4 5 R 3 8 R 4 0 R 3 7 R 4 8 R 5 0 R 3 5 R 4 2 R 3 2 R 3 3 R 8 0 R 8 1 R 7 9 R 7 7 R 7 8 R 8 3 ...

Page 108: ...16 S19400 1301 T14231 2 T14231 15 S19400 1501 S19400 2211 S19400 3323 T14231 11 S19400 2671 S19400 1001 T10812 41 S15161 19 T13640 12 S15128 9 S15128 4 10M 1 2W S19400 3321 68 5W 38J S16668 3 100pF 100 C O M M O N C B J L K N D M E F G A H R 3 R 5 0 0 C O N T R O L G 2 2 0 6 1 R1 R2 R3 R88 R61 R70 R73 R76 R85 R82 R87 R86 R60 R59 R69 R68 R72 R71 R75 R74 R84 R83 R78 R77 R79 R81 R80 R33 R32 R42 R35 R...

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