Lincoln Electric IDEALARC R3R 500-I Operating Manual
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Lincoln Electric IDEALARC R3R 500-I Operating Manual

Lincoln Electric IDEALARC R3R 500-I Operating Manual

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IDEALARC R3R 500-I & 600-I
R3R 500-I
K1380-A1
K1380-A2
K1380-A7
R3R 600-I
K1381-A1
K1381-A7
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.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS
OPERATING MANUAL
220/380/440V
380/500V
415V
TV
415V
SAFETY DEPENDS ON YOU
Most importantly, think before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
A.B.N. 36 000 040 308
IM 6000
May 2003

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Summary of Contents for Lincoln Electric IDEALARC R3R 500-I

  • Page 1 415V 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.

  • Page 2: Arc Welding Safety Precautions

    (MSDS) and overheat lifting chains or cables until they fail. follow your employer’s safety practices. h. Also see Item 7c. e. Also see Item 7b. Page 2 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 3 3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric. 4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Field Service Shop. (The “Lincoln Service Directory”...

  • Page 4: Welding, Emf & Pacemakers

    (This is also a good different from you and your pacemaker. practice to eliminate a common problem on welding - a poor work connection. • Do not work next to the welding power source. Page 4 Idealarc R3R 500-I & 600-I IM 6000...

  • Page 5: Instructions For Electromagnetic Compatibility

    Welding equipment should be connected to the mains supply reproduced from British Standard EN 50199) according to the manufacturer’s recommendations.If interference • for using with other Lincoln Electric/LiquidArc equipment. occurs, it may be necessary to take additional precautions such • designed for industrial and professional use.

  • Page 6: Product Description

    59 Amp 80 Amp 440 Volt 28 Amp 48 Amp 60 Amp 32 Amp 55 Amp 70 Amp 500 Volt 25 Amp 43 Amp 55 Amp 28 Amp 49 Amp 60 Amp Page 6 Idealarc R3R 500-I & 600-I IM 6000...

  • Page 7: Installation

    Install the reconnect panel for the proper input voltage per the diagram pasted inside the access panel cover. IM 6000 Idealarc R3R 500-I & 600-I Page 7...

  • Page 8: Operation

    The red light on the machine control panel indicates when The line contactor is energised. Note: If the amber High Temperature Warning Light is lit, it indicates that one or both of the protective thermostats has opened the line contactor. Page 8 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 9 Remote Output Current Control J. Ground F. POLARITY SWITCH (Factory installed option on domestic models only) Signifying the Earth (Ground) Connection Electrode Polarity Positive Electrode Polarity Negative Do Not Switch While Welding IM 6000 Idealarc R3R 500-I & 600-I Page 9...
  • Page 10 Turn the welder power switch on. Insert one end of the probe into the electrode holder and hold the other end on the work for approximately five seconds. AMMETER AND VOLTMETER – (factory installed options only) Page 10 IM 6000 Idealarc R3R 500-I & 600-I...

  • Page 11: Maintenance

    If any problems are encountered refer to your nearest authorised mountings during mega testing. Lincoln Field Service Shop. Short leads 201, 202, 203 & 204 together. (Away from ground and the PCB). IM 6000 Idealarc R3R 500-I & 600-I Page 11...

  • Page 12: Troubleshooting

    This column provides a course of action for the Possible Cause. If you do not understand or are unable to perform the Recommended Course of Action safely, contact you local Lincoln Authorised Field Service Facility. Page 12 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 13 Replace if defective. There are two thermostats; one on the secondary lead and one on the choke. Replace High Temperature Warning Light if defective. IM 6000 Idealarc R3R 500-I & 600-I Page 13...
  • Page 14 PC board connector. If welder has 2. Possible defective control board. but no control. any open circuit voltage, power SCR is defective. See Troubleshooting Procedures Page ?. 2. See PC board Troubleshooting Procedures Page ?. Page 14 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 15 2. Machine output shorted causing restarted. See Fault Protection overload protection on control board to Troubleshooting Page ?. operate. 3. Control circuit defective. 3. Replace per PC board, Troubleshooting, Page ?. IM 6000 Idealarc R3R 500-I & 600-I Page 15...
  • Page 16 3. Check per Page ?. 3. Current control potentiometer defective. 4. Repair or connect. 4. Lead or connection in control circuit open. 5. See SCR Troubleshooting, Page ?.. 5. Defective control or circuit boards. Page 16 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 17 5. Connect or repair. 5. Lead or connection in current control circuit open. 6. Connect plug. 6. Control PC board plug disconnected or loose. 7. Control circuit problems. 7. See SCR Troubleshooting, Page ?. IM 6000 Idealarc R3R 500-I & 600-I Page 17...
  • Page 18 TROUBLESHOOTING CONTROL CIRCUIT TROUBLESHOOTING CHART Page 18 Idealarc R3R 500-I & 600-I IM 6000...

  • Page 19: Troubleshooting Procedures

    If any other condition exists, refer to the Troubleshooting Guide. If either step (3) or step (4) fails, replace the switch. IM 6000 Idealarc R3R 500-I & 600-I Page 19...
  • Page 20 A good gate circuit will read a low resistance, b. AC leads X1, X2 and X3 from the anodes of the SCR’s but not zero ohms. and cathodes of the diodes. Page 20 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 21 NOTES IM 6000 Idealarc R3R 500-I & 600-I Page 21...
  • Page 22 AP-217-A Illustration of Sub-Assemblies Operative: May 2003 Supersedes: Page 22 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 23 AP-217-A.1 Operative: May 2003 Supersedes: Idealarc R3R 500-I & 600-I (for codes 1385 & above) Sub Assembly Item No. SUB ASSEMBLY PAGE NAME PAGE NO. AP217-B.1 AP217-B.2 AP217-C AP217-D AP217-E AP217-F AP217-G AP217-H AP217-J CODE NO. R3R 500-I (415V) 1456...
  • Page 24 NOTES Page 24 Idealarc R3R 500-I & 600-I IM 6000...

  • Page 25: Optional Equipment

    Pocket Amptrol .............Order call IM 6000 Idealarc R3R 500-I & 600-I Page 25...

  • Page 26: Control Panel Assembly

    AP-217-C Control Panel Assembly Operative: May 2003 Supersedes: Part of 9A Page 26 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 27 This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates. IM 6000 Idealarc R3R 500-I & 600-I Page 27...

  • Page 28: Case Front Assembly

    AP-217-D Case Front Assembly Operative: May 2003 Supersedes: Page 28 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 29 This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [] have purposely been left blank so as to eliminate errors, confusion and updates. IM 6000 Idealarc R3R 500-I & 600-I Page 29...
  • Page 30 3 Phase Bridge Assembly Operative: May 2003 Supersedes: 22E 22B 22C 22D 19E19F 6B 6C 14A 14B 14C Sleeving Not Sold 2C 19B 15B 15C 14B 14C 14D 3B 3D Part of 20A Page 30 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 31 Shunt (R3R 600-I) S6602-20 3/8-16 x 1.00 Hex Head Cap Screw Lock Washer 3/8” 3/8-16 Hex Nut Sems Screw T10082-3 #10-24 Hex Nut Thread Form Screw S9225-47 Spacer T7028-113 Brace T8477-35 IM 6000 Idealarc R3R 500-I & 600-I Page 31...
  • Page 32 AP-217-F Input Box & Fan Assembly Operative: May 2003 Supersedes: 7A 7H 7B Page 32 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 33 1/4-20 Hex Nut Heavy Hex Nut 1/4” Grommet Strip T12823-15 E2521/1-.010-5.13-7.20 Insulation Self Tapping Screw AS12733-3Z Bushing T12380-2 Ground Decal T13259 Connection Diagram (415V) AT3164-1 Connection Diagram (380/500V) AT3170-1 Connection Diagram (220/380/44) AM3237 IM 6000 Idealarc R3R 500-I & 600-I Page 33...
  • Page 34 AP-217-G Centre Assembly Operative: May 2003 Supersedes: Page 34 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 35 Plain Washer S9262-30 5/16” Lock Washer 5/16-18 Hex Nut Spring Washer T12735 5/16-18 x 1.50 Hex head Cap Screw Insulating Tube T7028-171 Insulating Tube T7028-113 Plain Washer S9262-121 Lock Washer E106A-14 IM 6000 Idealarc R3R 500-I & 600-I Page 35...

  • Page 36: Transformer Assembly

    AP-217-H Transformer Assembly Operative: May 2003 Supersedes: Page 36 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 37 Choke Coil M14217-1 R3R 600-I Choke Coil M14217-2 R3R 500-I Lamination Assembly L6268-3 R3R 600-I Lamination Assembly L6268-4 Stud AS4324-6 Plain Washer S9262-120 Lock Washer T9860-4 3/8-16 Hex Nut Secondary Thermostat T13359-2 IM 6000 Idealarc R3R 500-I & 600-I Page 37...

  • Page 38: Cover Assembly

    AP-217-J Cover Assembly Operative: May 2003 Supersedes: Page 38 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 39 Recommended Spare Parts are highlighted in bold ITEM DESCRIPTION PART NO. QTY. Cover Seal S12934 Roof AM2805-10R Self Tapping Screw AS1733-3Z Side Panel AM2804-1R Self Tapping Screw AS1733-3Z Warning Decal M16196 Warranty Decal S22127-2 Wiring Diagram AL2401 IM 6000 Idealarc R3R 500-I & 600-I Page 39...

  • Page 40: Wiring Diagram

    Wiring Diagram Page 40 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 41 Wiring Diagram IM 6000 Idealarc R3R 500-I & 600-I Page 41...
  • Page 42 NOTES Page 42 Idealarc R3R 500-I & 600-I IM 6000...
  • Page 43 NOTES IM 6000 Idealarc R3R 500-I & 600-I Page 43...
  • Page 44 We respond to our customers based on the best information in our authorised Kubota service dealer) possession at that time. Lincoln Electric is not in a position to warrant or guarantee Ruggerini Engines and Accessories such advice and assumes no liability, with respect to such information or advice. We...

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Idealarc r3r 600-i

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