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Lincoln Electric IDEALARC R3R 500-I, Operating Manual, Page: 1 / 44

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Lincoln Electric IDEALARC R3R 500-I Operating Manual Download Page 1

IM 6000

May 2003

OPERATING MANUAL

THE LINCOLN ELECTRIC COMPANY

(AUSTRALIA) PTY. LTD. 

A.B.N. 36 000 040 308

SYDNEY. AUSTRALIA

A Subsidiary of

THE LINCOLN ELECTRIC CO. U.S.A.

Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.

THE WORLD’S LEADER IN WELDING AND CUTTING PRODUCTS

SAFETY DEPENDS ON YOU

Lincoln Electric welders are designed and built with safety in mind. However, your overall safety can be

increased by proper installation and thoughtful operation on your part. Read and observe the general safety

precautions on page 2 and follow specific installation and operating instructions included in this manual.

Most importantly, think before you act and be careful.

IDEALARC R3R 500-I & 600-I

R3R 500-I

K1380-A1

220/380/440V

K1380-A2

380/500V

K1380-A7

415V

R3R 600-I

K1381-A1

TV

K1381-A7

415V

Summary of Contents for IDEALARC R3R 500-I

Page 1: ...PENDS ON YOU Lincoln Electric welders are designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part Read and obse...

Page 2: ...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 e Also see I...

Page 3: ...fety 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 m...

Page 4: ...welding can interfere with a pacemakers function Generally the interference does not permanently damage the pacemaker Once the wearer leaves the arc welding environment or stops welding the pacemaker...

Page 5: ...welding or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surroun...

Page 6: ...DC Output Range 60 Amp 22 Volt 45 Amp 22Volt 550 Amp 40 Volt 375 Amp 35 Volt Input Current and Circuit Protection HRC superlag HRC superlag Rated Max fuse in Amps Rated Max fuse in Amps Input Voltage...

Page 7: ...R CONNECTION ELECTRIC SHOCK can kill Have an electrician install and service this equipment Turn the input power off at the fuse box before working on equipment Do not touch electrically hot parts Rem...

Page 8: ...te If the amber High Temperature Warning Light is lit it indicates that one or both of the protective thermostats has opened the line contactor OUTPUT CONTROL The current control dial labelled I on th...

Page 9: ...H Output Current Control Dial Range A Output Current Control Dial Range B E OUTPUT CURRENT CONTROL MACHINE REMOTE SWITCH Remote Output Current Control F POLARITY SWITCH Factory installed option on dom...

Page 10: ...cable connection to the welder a On the R3R 500 I and R3R 600 I the welder Current Control labelled switch must be in the Remote position and the Current Dial Selector switch in the B range With the...

Page 11: ...1 1 Disconnect input power mains supply 2 Remove welding leads electrode cables and work lead from the machine before any tests are carried out 3 Remove all connections from the PCB Install a shortin...

Page 12: ...rstand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorised Field Service Facility ELECTRIC SHOCK can kill Do not touch electrically hot parts Have an...

Page 13: ...perature Warning Light should be lit RECOMMENDED COURSE OF ACTION 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...

Page 14: ...ontactor 6 Latching resistor R3 open 7 Control circuit problems 1 Possible defective power SCR 2 Possible defective control board RECOMMENDED COURSE OF ACTION 1 Repair connections 2 Repair 3 Replace b...

Page 15: ...3 Fan inoperative 4 Shorted diode or SCR in power rectifier bridge 1 Excessive load causing the overload protection on control board to operate 2 Machine output shorted causing overload protection on...

Page 16: ...ntactor 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...

Page 17: ...ted 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 disc...

Page 18: ...ads and correct 202 203 120V 10 Remove and replace Gate leads G 1 G 2 G 3 from PC board one at a time If aux voltages are incorrect If aux voltages If removing each gate lead If removing and replacing...

Page 19: ...f the machine is overloaded for 2 to 3 seconds The overload values are as appears in the following table F CHECKING SNUBBER CIRCUIT In case of an SCR malfunction or failure the snubber assembly should...

Page 20: ...2 POWER DIODE TEST a Establish the polarity of the ohmmeter leads and set to X10 scale b Connect the ohmmeter positive lead to anode and negative lead to the cathode c Reverse the leads of the ohmmet...

Page 21: ...IM 6000 Idealarc R3R 500 I 600 I Page 21 NOTES...

Page 22: ...Page 22 Idealarc R3R 500 I 600 I IM 6000 Illustration of Sub Assemblies AP 217 A Operative May 2003 Supersedes NEW 6 8 3 4 5 2 7 1...

Page 23: ...2 1 1446 1 1 1 1 1 1 2 1 1475 1 1 1 1 1 1 2 1 1573 1 1 1 1 1 1 2 1 1681 1 1 1 1 1 1 2 1 1694 1 1 1 1 1 1 2 1 1704 1 1 1 1 1 1 2 1 R3R500 I 380 500 1 1 1 1 1 1 3 1 1458 1 1 1 1 1 1 3 1 1705 1 1 1 1 1...

Page 24: ...Page 24 Idealarc R3R 500 I 600 I IM 6000 NOTES...

Page 25: ...gas cylinder Order KA1237 Remote Control 8 5m 6 pin Order K857 Remote Control 20m 6 pin Order K857 20 Foot Amptrol Order K870 Hand Amptrol for LA 9 LA 17 LW 20 TIG Torches Order K963 1 Hand Amptrol fo...

Page 26: ...Page 26 Idealarc R3R 500 I 600 I IM 6000 Control Panel Assembly AP 217 C Operative May 2003 Supersedes NEW 13 14 9 9 Part of 9A 12A 12 1 17 17A 2 19 3 9A 5 15 9A 6 5 22 23A 23C 23B...

Page 27: ...not shown S17062 2 1 x 19 Pilot Light High Temperature Amber AT3385 1 1 x 22 PCB Assembly R3R 500 I G1574 1 x 22 PCB Assembly R3R 600 I G1575 1 x 22B Expansion Nut not shown S14020 3 7 x 22C Self Tap...

Page 28: ...ge 28 Idealarc R3R 500 I 600 I IM 6000 Case Front Assembly AP 217 D Operative May 2003 Supersedes NEW 6A 6B 1 14 4C 13 15A 15B 12A 16A 16B 16C 16A 16B 16C 7B 11A 11B 10A 7A 7C 10B 4A 7C 7A 9A 9B 12B 4...

Page 29: ...025 60 2 x 11A PC Board Snubber AM2538 1 x 11B Self Tapping Screw 4 x 12A Air Deflector R3R 600 I S17113 1 x 12B Self Tapping Screw AS1733 3Z 2 x 13 Bushing T12380 2 1 x 14 Ground Decal T13260 4 1 x 1...

Page 30: ...tive May 2003 Supersedes NEW 21 21 2D 2E 2B 2D 2E 3B 3D Part of 20A 20B 3A 3C 3B 15E 15D 15A 20A 19D 2C 19B 17 19C Sleeving Not Sold 15B15C 14B14C14D 11A 2B 2A 19A 16A 16B 19E19F 23B 23A 24 4 4 13 6B...

Page 31: ...6 18 x 1 25 Hex Head Cap Screw 3 x 15C Plain Washer S9262 121 3 x 15D Lock Washer 3 x 15E 5 16 18 Hex Nut 3 x 16A 5 16 18 x 1 00 Hex Head Cap Screw 2 x 16B Plain Washer 5 16 4 x 16C Lock Washer 5 16 2...

Page 32: ...Page 32 Idealarc R3R 500 I 600 I IM 6000 Input Box Fan Assembly AP 217 F Operative May 2003 Supersedes NEW 4G 4G 4C 4D 4E 4E 4C 4F 4A 8 1A 7F 5C 1B 4H 6B 6A 7G 7A 7H 7B 7C 7D 5A 5B 3B 3A 2A 2B 9 10...

Page 33: ...ontactor R3R 500 I M12161 80 1 x 5A Contactor R3R 600 I M18712 1 x 5B Self Tapping Screw AS1733 3Z 3 x 5C Rectifier Bridge 6A Control Transformer 415V AM2434 1 x 6A Control Transformer multi voltage A...

Page 34: ...Page 34 Idealarc R3R 500 I 600 I IM 6000 Centre Assembly AP 217 G Operative May 2003 Supersedes NEW 1 5 6A 6C 6B 6 6B 9A 2A 2B 2C 9B 7B 7A 3 5...

Page 35: ...ffle bottom w Pocket Amptrol option only S17103 1 1 x 10B Self Tapping Screw S8025 65 4 x 11 Diode heat Sink Assembly includes w Pocket Amptrol option only M16456 1 x 11A heatsink S17053 1 x 11B SCR D...

Page 36: ...Page 36 Idealarc R3R 500 I 600 I IM 6000 Transformer Assembly AP 217 H Operative May 2003 Supersedes NEW 5 6 7D 7C 7B 7A 8 1 3 2 6 7B 7C 7D...

Page 37: ...3 x R3R 500 I 2 Primary Coils bottom 415V 9878 5B 3 x 2 Primary Coils bottom TV 9879 5B 3 x 2 Primary Coils bottom DV 9880 5B 3 x R3R 600 I 2 Primary Coils bottom TV 9889 5B 3 x 2 Primary Coils bottom...

Page 38: ...Page 38 Idealarc R3R 500 I 600 I IM 6000 Cover Assembly AP 217 J Operative May 2003 Supersedes NEW 1 2A 5 2B 3A 6 4 3B...

Page 39: ...1 x 2B Self Tapping Screw AS1733 3Z 2 x 3A Side Panel AM2804 1R 2 x 3B Self Tapping Screw AS1733 3Z 18 x 4 Warning Decal M16196 1 x 5 Warranty Decal S22127 2 1 x 6 Wiring Diagram AL2401 1 x Use only...

Page 40: ...Wiring Diagram Note This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of...

Page 41: ...Wiring Diagram Note This diagram is for reference only It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of...

Page 42: ...Page 42 Idealarc R3R 500 I 600 I IM 6000 NOTES...

Page 43: ...IM 6000 Idealarc R3R 500 I 600 I Page 43 NOTES...

Page 44: ...le for the operation non operation or malfunction of any such battery CONDITION OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorised Service Facility abou...

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