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E-3

TROUBLESHOOTING

E-3

IDEALARC® R3R 375-I, 500-I AND 600-I

Observe all Safety Guidelines detailed througout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility 
for technical troubleshooting assistance before you proceed.

CAUTION

FUNCTION PROBLEMS

PROBLEMS

(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDED

COURSE OF ACTION

C. Machine input contactor closes

but has no or low output. Open
circuit voltage should be 67 to 71
volts.

D. Machine has maximum output

but no control.

1. Electrode 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 to machine.

5. Connect input lead.

6. a. Replace.

b. Check leads to the resistor

and repair if defective.

7. See Troubleshooting Procedures

– Power Silicon Controlled
Rectifier.

1. Remove all gate leads G1, G2

and G3 at PC board connector
J4. If welder has any open circuit
voltage, power SCR is defective.
See Troubleshooting Procedures
Section J.

2. See PC board Troubleshooting

Procedures Section A

All manuals and user guides at all-guides.com

Summary of Contents for IDEALARK RSR 375-I

Page 1: ...PAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machine Code Numbers above 9535...

Page 2: ...T 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 Cutt...

Page 3: ...neously 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 f...

Page 4: ...cent 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 hazardo...

Page 5: ...ammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans reve...

Page 6: ...ect replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement in...

Page 7: ...Power Connection A 1 Duty Cycle A 1 Output Connections A 1 Operating Instructions Section B Accessories Section C Maintenance Section D Troubleshooting Section E Troubleshooting Procedures E 7 E 10 Wi...

Page 8: ...tud 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...

Page 9: ...e 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 rang...

Page 10: ...rent 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 Tra...

Page 11: ...irectly to the 6 pin Amphenol on the front of the power source POCKET AMPTROL factory installed only The Pocket Amptrol option provides a remote current control for the R3R welders This wireless contr...

Page 12: ...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 giv...

Page 13: ...ute 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 o...

Page 14: ...il 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 sh...

Page 15: ...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...

Page 16: ...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 pow...

Page 17: ...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 swit...

Page 18: ...ional 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 mo...

Page 19: ...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 termin...

Page 20: ...r the control circuit 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 ver...

Page 21: ...f either 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 fiel...

Page 22: ...nce 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 Rev...

Page 23: ...RY 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...

Page 24: ...F 2 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 the enclosu...

Page 25: ...R3R 375 I 500 I AND 600 I F 3 R3R 375 I 500 I and 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 All manuals and...

Page 26: ...e 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 l...

Page 27: ...und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci n de...

Page 28: ...bsidiaries 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 All manuals and...

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