Lincoln Electric IDEALARC R3R-300 Service Manual
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Lincoln Electric IDEALARC R3R-300 Service Manual

Lincoln Electric IDEALARC R3R-300 Service Manual

Lincoln electric welder user manual
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See also: Operator's Manual
RETURN TO MAIN INDEX
SVM139-A
June 1998
®
IDEALARC
R3R-300, -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.

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

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Summary of Contents for Lincoln Electric IDEALARC R3R-300

  • Page 1: Service Manual

    RETURN TO MAIN INDEX SVM139-A June 1998 ® IDEALARC R3R-300, -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 .

  • Page 2: Safety

    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.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can kill. 3.a. 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.
  • Page 4 WELDING SPARKS can 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc Protegez-vous contre la secousse électrique: Les circuits à...

  • Page 6: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS Safety...i-iv Installation ...Section A Technical Specifications ...A-2 Safety Precautions...A-5 Select Suitable Location (Stacking, Tilting, Lifting) ...A-5 Input Connections...A-6 Reconnect Procedure ...A-8 Output Connections (Stick, TIG, Air/Carbon Arc Cutting) ...A-9 Operation...Section B Safety Instructions ...B-2 General Description ...B-3 Controls and Settings ...B-4 Welding Operation ...B-6...
  • Page 7 Section A-1 - INSTALLATION SECTION - Installation ...Section A Technical 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...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - IDEALARC R3R-300 INPUT - THREE PHASE ONLY Standard Voltage 230V 460V Duty Cycle 100% Current Range 45 to 375 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES AT 60% DUTY CYCLE Input Voltage / Fuse Frequency (Super Lag)

  • Page 9: Technical Specifications, Idealarc R3R-400

    TECHNICAL SPECIFICATIONS - IDEALARC R3R-400 INPUT - THREE PHASE ONLY Standard Voltage 230V 460V Duty Cycle 100% Current Range 60 to 500 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES AT 60% DUTY CYCLE Input Voltage / Fuse Frequency (Super Lag) or Breaker Size Volts/Hz 230/60...

  • Page 10: Technical Specifications, Idealarc R3R-500

    TECHNICAL SPECIFICATIONS - IDEALARC R3R-500 INPUT - THREE PHASE ONLY Standard Voltage 230V 460V Duty Cycle 100% Current Range 75 to 625 Amps RECOMMENDED INPUT WIRE AND FUSE SIZES AT 60% DUTY CYCLE Input Voltage / Fuse Frequency (Super Lag) or Breaker Size Volts/Hz 230/60...

  • Page 11: Safety Precautions

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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.

  • Page 12: Input Connections

    (CR1) and reconnect panel assem- bly for multiple voltage machines. GROUND CONNECTION The welder frame must be grounded. A stud marked with the symbol box is provided for this purpose. National Electrical Code for details on proper ground- ing methods.

  • Page 13: Input Wire And Fuse Size

    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. IDEALARC R3R appropriate Technical...

  • Page 14: Reconnect Procedure

    LINES INPUT CONTACTOR PILOT TRANSF. THE LINCOLN ELECTRIC CO., CLEVELAND OHIO U.S.A. INSTALLATION 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.

  • Page 15: Output Connections (Stick, Tig, Air/Carbon Arc Cutting

    (60% Duty 68 mm Cycle) INSTALLATION NOTE: If the welder comes equipped with the polarity switch option, the output terminals are labeled “electrode” and “to work.” The output terminals are energized at all times. 1. NEGATIVE (-) WELDING CABLE CONNECTION 2.
  • Page 16 A-10 A-10 NOTES IDEALARC R3R...
  • Page 17 Section B-1 - 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 TABLE OF CONTENTS IDEALARC R3R Section B-1...

  • Page 18: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section of operating instructions before operating the machine. SAFETY INSTRUCTIONS • Insulate yourself from the work and ground. • Always wear dry insulating gloves. • Do not weld on containers that have held com- bustibles.

  • Page 19: General Description

    The R3R-300 uses a single range potentiometer con- trol. The R3R-400 and R3R-500 have separate low and high range controls. The welder’s unique combi- nation of 3 phase transformer, SCR/Diode bridge rec- tifier, arc control choke, and solid state control system deliver outstanding arc characteristics.

  • Page 20: Controls And Settings

    CONTROLS AND SETTINGS All operator controls and settings are located on the case front assembly. See Figure B.1 for their loca- tions. FIGURE B.1 – CASE FRONT CONTROLS 1. Power Source Pilot Light 2. ON/OFF Power Toggle Switch 3. Arc Force Control 4.
  • Page 21 8. POLARITY 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): voltage. 11. THERMAL PROTECTION INDICATOR LIGHT: This amber light indicates that either of the two protective thermostats has opened.

  • Page 22: Welding Operation

    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.
  • Page 23 Section C-1 - ACCESSORIES SECTION - Accessories...Section C Options/Accessories...C-2 Factory Installed Options ...C-2 Polarity Switch ...C-2 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...

  • Page 24: Accessories

    Idealarc R3R from your local Lincoln Distributor. Remote Current Control (K857) - Portable current 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.

  • Page 25: Routine And Periodic Maintenance

    Section D-1 Section D-1 TABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ...Section D Safety Precautions...D-2 Routine and Periodic Maintenance ...D-2 General Component Locations...D-3 IDEALARC R3R...

  • Page 26: Maintenance

    SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified 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:...

  • Page 27: General Component Locations

    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.
  • Page 28 NOTES IDEALARC R3R...
  • Page 29 Section E-1 - THEORY OF OPERATION SECTION - Theory of Operation ...Section E General Description ...E-2 Input Line Voltage, Contactor and Main Transformer...E-2 Output Mode and Control, Rectification and Feedback ...E-3 Optional Polarity Switch and Amptrol Circuits ...E-4 Protective Devices and Circuits...E-5 SCR Operation ...E-6 CONTROL TRANSFORMER...

  • Page 30: Theory Of Operation

    SWITCH INPUT CONTACTOR GENERAL DESCRIPTION The Idealarc R3R 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.
  • Page 31 THEORY OF OPERATION FIGURE E.3 – OUTPUT RECTIFICATION, CONTROL, AND FEEDBACK CONTROL TRANSFORMER MOTOR POWER SWITCH THERMOSTATS INPUT CONTACTOR OUTPUT RECTIFICATION, CONTROL, AND FEEDBACK The three-phase AC output from the main transformer secondary is rectified and controlled through the SCR/ diode bridge.

  • Page 32: Optional Polarity Switch And Amptrol Circuits

    THEORY OF OPERATION FIGURE E.4 – OPTIONAL POLARITY SWITCH AND POCKET AMPTROL CIRCUITS CONTROL TRANSFORMER MOTOR POWER THERMOSTATS SWITCH INPUT CONTACTOR 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.

  • Page 33: Protective Devices And Circuits

    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.

  • Page 34: Scr Operation

    THEORY OF OPERATION 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.
  • Page 35 Section F-1 - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section ...Section F How to Use Troubleshooting Guide...F-2 PC Board Troubleshooting Procedures ...F-3 Troubleshooting Guide...F-4 - F-9 Test Procedures Input Contactor Test (Equipped with AC Coil) ...F-10 Input Contactor Test (R3R 300 Equipped with DC Coil)...F-13 Control Transformer (T2) Voltage Test ...F-16 Main Transformer (T1) Voltage Test ...F-19 Static SCR/Diode Rectifier Bridge Test...F-24...

  • Page 36: Troubleshooting And Repair

    TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE 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 Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 37: Pc Board Troubleshooting Procedures

    • 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.

  • Page 38: Troubleshooting Guide

    NOT on. 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.
  • Page 39 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.
  • Page 40 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.
  • Page 41 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. detailed in the beginning of this manual.
  • Page 42 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.
  • Page 43 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. POSSIBLE AREAS OF...

  • Page 44: Input Contactor Test (Equipped With Ac Coil

    TROUBLESHOOTING & REPAIR (FOR MODELS EQUIPPED WITH AC COIL ON INPUT CONTACTOR) 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.
  • Page 45 F-11 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.1 – AC COIL INPUT CONTACTOR CONNECTIONS TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and the reconnect panel cover. 3.
  • Page 46 F-12 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.2 – AC COIL INPUT CONTACTOR TEST POINT LOCATIONS REMOVED) TEST FOR CONTACT CONTINUITY 1. Disconnect the main input supply power to the machine. 2. Remove the three leads connected to the input contactor coil, #233 and X1/#232.

  • Page 47: Input Contactor Test (R3R 300 Equipped With Dc Coil

    TROUBLESHOOTING & REPAIR (FOR R3R 300 EQUIPPED WITH DC COIL ON INPUT CONTACTOR) 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.
  • Page 48 F-14 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.3 – DC COIL INPUT CONTACTOR CONNECTIONS 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.
  • Page 49 F-15 TROUBLESHOOTING & REPAIR INPUT CONTACTOR TEST (continued) FIGURE F.4 – DC COIL INPUT CONTACTOR TEST POINT LOCATIONS REMOVED) 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, #232A and #233A.

  • Page 50: Control Transformer (T2) Voltage Test

    TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST 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.
  • Page 51 F-17 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.5 – CONTROL TRANSFORMER AND LEAD LOCATIONS TEST PROCEDURE 1. Disconnect the main input supply power to the machine. 2. With the 5/16” nut driver, remove the top, case sides, and lower the front control panel.
  • Page 52 F-18 TROUBLESHOOTING & REPAIR CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.6 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS 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.

  • Page 53: Main Transformer (T1) Voltage Test

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST 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.
  • Page 54 F-20 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.7 – INPUT CONTACTOR, RECONNECT PANEL, AND PRIMARY LEADS TO MAIN TRANSFORMER LOCATIONS TEST PROCEDURE 1. Set the ON/OFF power switch to OFF. 2. Disconnect main input supply power from the machine.
  • Page 55 F-21 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.8 – MAIN SECONDARY LEAD TEST POINTS 8. Read the meter. a. If proper voltage is present for all three phases, proper main input supply volt- age is being supplied. b.
  • Page 56 F-22 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) PHASE ANGLE WINDING TEST 12. Test with an AC voltmeter for approximate- ly 66VAC at each phase winding. leads #201, #202, #203, and #204 per Table F.1. For control board #G2206, see Figure F.9 for lead locations.
  • Page 57 F-23 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER (T1) VOLTAGE TEST (continued) FIGURE F.9 – CONTROL BOARD G2206 - [ Plug P4 FIGURE F.10 – CONTROL BOARD G1575 - [ TABLE F.1 – PHASE ANGLE WINDING VOLTAGES From Lead # ] TEST POINTS R3R CONTROL G2206 - [ ] TEST POINTS...

  • Page 58: Static Scr/Diode Rectifier Bridge Test

    TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST 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.
  • Page 59 F-25 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) 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. 2. With the 5/16” nut driver, remove the case top and sides and lower the front panel.
  • Page 60 F-26 F-26 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.13 – SNUBBER BOARD M15370 PLUG P5 LOCATION Plug P5 M15370-[ ] SNUBBER FIGURE F.14 – RESISTOR R3 LOCATION RESISTOR R3 IDEALARC R3R...
  • Page 61 F-27 TROUBLESHOOTING & REPAIR STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.15 – HEAT SINK AND SCR TEST POINTS REMOVE INSULATING PAINT 7. Remove the red insulating paint from the heat sink test points. See Figure F.15. NOTE: Do not disassemble the heat sink. 8.

  • Page 62: Active Scr Test

    F-28 TROUBLESHOOTING & REPAIR 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.
  • Page 63 F-29 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) FIGURE F.16 – CONTROL BOARD PLUG P1 AND P3 LOCATIONS R3R CONTROL G2206 - [ Plug P4 (Removed) FIGURE F.18 – SNUBBER BOARD PLUG P5 LOCATION M15370-[ ] SNUBBER TEST PROCEDURE 1. Disconnect the main input supply power to the machine.
  • Page 64 F-30 TROUBLESHOOTING & REPAIR ACTIVE SCR TEST (continued) FIGURE F.20 – SCR TESTER CIRCUIT AND SCR CONNECTIONS REMOVE INSULATING PAINT 7. Remove the red insulating paint from the heat sink test points. See Figure F.20. NOTE: Do not disassemble the heat sinks. 8.

  • Page 65: Pocket Amptrol Circuit Test

    TROUBLESHOOTING & REPAIR POCKET AMPTROL CIRCUIT TEST 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.
  • Page 66 F-32 TROUBLESHOOTING & REPAIR POCKET AMPTROL CIRCUIT TEST (continued) FIGURE F.21 – T3 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.
  • Page 67 F-33 TROUBLESHOOTING & REPAIR POCKET AMPTROL CIRCUIT TEST (continued) FIGURE F.22 – POCKET AMPTROL BOARD PLUG P6 AND P7 LOCATION 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.
  • Page 68 F-34 TROUBLESHOOTING & REPAIR POCKET AMPTROL CIRCUIT TEST (continued) FIGURE F.23 – SENSING RESISTOR R4 FIGURE F.24 – POCKET AMPTROL SIMPLIFIED DRAWING #219 #218 2 J6 POCKET AMPTROL 1J 6 TRANSFORMER (T3) POCKET #201A GREEN AMPTROL YELLOW P.C. GREEN BOARD #203A MACHINE REMOTE...

  • Page 69: Normal Open Circuit Voltage Waveform

    F-35 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING – NO LOAD 5 ms 50 volts 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.

  • Page 70: Typical Output Voltage Waveform-Machine Loaded

    F-36 TROUBLESHOOTING & REPAIR TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED 5 ms 20 volts 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.

  • Page 71: Typical Scr Gate Voltage Waveform

    F-37 TROUBLESHOOTING & REPAIR TYPICAL SCR GATE VOLTAGE WAVEFORM MAXIMUM OUTPUT SETTING – NO LOAD 5 ms 2 volts This is the typical SCR gate pulse voltage waveform. The machine was 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.
  • Page 72 F-38 TROUBLESHOOTING & REPAIR ABNORMAL OUTPUT VOLTAGE WAVEFORM ONE OUTPUT SCR NOT FUNCTIONING 50 volts This is NOT the typical DC output voltage waveform. One output SCR is not functioning. Note the “GAP” in the waveform. One SCR gate is dis- connected to simulate an open or non-functioning output SCR.

  • Page 73: Input Contactor (Cr1) Cleaning/Replacement

    TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT 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.
  • Page 74 F-40 TROUBLESHOOTING & REPAIR INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F.25 – INPUT CONTACTOR CLEANING AND REMOVAL 1. INPUT SUPPLY LINE 2. INPUT CONTACTOR CR1 3. RECONNECT PANEL CLEANING PROCEDURE 1. Remove the main input supply power to the machine. 2.

  • Page 75: Fan Motor And Blade Removal And Replacement

    TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT 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-...
  • Page 76 F-42 TROUBLESHOOTING & REPAIR FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.26 – FAN MOTOR MOUNTING DETAILS PROCEDURE 1. Remove the main input supply power to the machine. 2. Using the 5/16” nut driver, remove the case top and sides. 3.

  • Page 77: Scr/Diode Rectifier Assembly Removal And Replacement

    SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT 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-...
  • Page 78 F-44 TROUBLESHOOTING & REPAIR SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued) FIGURE F.27 – SCR/DIODE ASSEMBLY DETAILS GLASTIC STIFFENERS PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. panel.

  • Page 79: Troubleshooting

    F-45 SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued) REASSEMBLY 13. For reassembly, carefully place the SCR/ diode assembly into position on the mounting brackets. 14. Replace and tighten the four nuts and lockwash- ers that hold the SCR/diode assembly to the mounting brackets.

  • Page 80: Scr Removal And Replacement

    TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT 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.
  • Page 81 SCR mounting surfaces. 9. Apply a thin (0.001” to 0.003”) layer of PEN- ETROX A-13 (Lincoln Electric #E2529) or PENETROX A, heat sink compound, to each heat sink’s SCR mounting surface.
  • Page 82 F-48 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.29 – 1/2” WIDE LEAF SPRING 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.
  • Page 83 F-49 TROUBLESHOOTING & 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.
  • Page 84 F-50 TROUBLESHOOTING & REPAIR SCR REMOVAL AND REPLACEMENT (continued) FIGURE F.31 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING STEEL PRESSURE PAD PROCEDURE FOR THE 5/8 INCH WIDE SPRING 1. Place a piece of sleeving around each cap screw.
  • Page 85 F-51 TROUBLESHOOTING & 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.

  • Page 86: Mounting Of Stud Type Diodes To Aluminum Heat Sinks

    TROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM 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.
  • Page 87 F-53 TROUBLESHOOTING & REPAIR MOUNTING OF STUD TYPE DIODES TO ALUMINUM PROCEDURE 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides. 3. Loosen the appropriate diode nut and remove the diode that is to be replaced.

  • Page 88: Main Transformer Removal And Replacement

    TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL AND REPLACEMENT 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-...
  • Page 89 F-55 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) FIBER BAFFLES BASE MOUNTING BOLTS (4) CHOKE MAIN TRANSFORMER REMOVAL OF LIFT BAIL 1. Remove the main input supply power to the machine. 2. With the 5/16” nut driver, remove the case top and sides.
  • Page 90 F-56 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) BOTTOM "E" IRON REMOVAL OF CHOKE AND TOP IRON ASSEMBLY 1. Remove the two (left and right) glastic stiffen- ers connecting the negative rectifier plate and choke assembly to the main transformer thru-bolts.
  • Page 91 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.
  • Page 92 Place the coils so that the leads come out at the back of the machine. See Figure F.36 for proper positioning. 4. Place insulation (Lincoln Electric part number S20728) on top of each of the three primary coils. The longer side of the insulation should be placed toward the front of the machine.
  • Page 93 F-59 F-59 TROUBLESHOOTING & REPAIR 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 IDEALARC R3R...
  • Page 94 F-60 TROUBLESHOOTING & REPAIR MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) REASSEMBLING THE MAIN TRANSFORMER INTO THE MACHINE 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 machine.

  • Page 95: Retest After Repair

    F-61 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR (R3R 300) Retest a machine: • If 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 • If you repair or replace any electrical components. Input Volts/Phase/Hertz 200/3/60 208/3/60...
  • Page 96 F-62 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR (R3R 400) Retest a machine: • If 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 • If you repair or replace any electrical components. Input Volts/Phase/Hertz 200/3/60 208/3/60...
  • Page 97 F-63 TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR (R3R 500) Retest a machine: • If 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 • If you repair or replace any electrical components. Input Volts/Phase/Hertz 200/3/60 208/3/60...
  • Page 98 F-64 F-64 NOTES IDEALARC R3R...
  • Page 99 ELECTRICAL DIAGRAMS 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 IDEALARC R3R...

  • Page 101: Electrical Diagrams Section

    ELECTRICAL DIAGRAMS Wiring Diagram-R3R-300 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

  • Page 102: Wiring Diagram - R3R-400 (Code 9537

    ELECTRICAL DIAGRAMS Wiring Diagram - R3R-400 (Code 9537) DEC 97 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

  • Page 103: Wiring Diagram - R3R-400 (Code 9874), R3R-500

    ELECTRICAL DIAGRAMS Wiring Diagram - R3R-400 (Code 9874), R3R-500 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.

  • Page 104: Pocket Amptrol Schematic

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not 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.

  • Page 105: Snubber Board Schematic & Layout

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not 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.

  • Page 106: R3R-300 Control Pc Board

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not 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.

  • Page 107: R3R-400 Control Pc Board

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not 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.

  • Page 108: R3R-500 Control Pc Board

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty. Individual Printed Circuit Board Components are not 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.

This manual is also suitable for:

Idealarc r3r-500Idealarc r3r-400

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