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IM275
September 1993
Idealarc R3R-300, R3R-400, R3R-500
7135; 7152; 7198; 7304; 7308; 7348; 7360; 7361;
7362; 7363; 7435; 7480; 7481; 7491; 7515; 7518;
7532; 7539; 7540; 7541; 7542; 7543; 7544; 7545;
7546; 7547; 7548; 7549; 7554; 7570; 7571; 7572;
7584; 7585; 7586; 7587; 7598; 7599; 7600; 7601;
7602; 7603; 7604; 7605; 7609; 7689; 7709; 7710;
7726; 7727; 7728; 7730; 7734; 7735; 7739; 7740;
7741; 7791
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Summarization of Contents
Safety Depends on You
Electric Shock Hazards
Precautions to prevent electric shock during welding operations.
Fumes and Gases Hazards
Risks from welding fumes and gases, and ventilation requirements.
Welding Sparks and Fire Hazards
Preventing fires and explosions from welding sparks and hot materials.
Arc Rays Hazards
Protecting eyes and skin from arc rays and spatter.
Cylinder Explosion Hazards
Safety measures for handling compressed gas cylinders to prevent explosion.
Electrical Equipment Safety
Safe installation and maintenance for electrically powered welding equipment.
Engine Powered Equipment Safety
Operating and maintenance safety for engine-powered welding equipment.
Electric and Magnetic Field Hazards
Health effects of EMF fields and methods to minimize exposure.
Foreign Language Safety
Safety warnings presented in multiple languages, including French and Spanish.
Transformer and Rectifier Safety
Specific safety precautions for transformer and rectifier welding machines.
INSTALLATION
Location and Stacking
Guidelines for properly installing and stacking the welding machines to ensure optimal performance and safety.
Output Connections
Instructions for connecting electrode and work cables to the machine's output studs.
Input Wiring
Guidance on connecting the three-phase AC power supply to the welder, including grounding requirements.
Optional Remote Control Connection
Procedure for connecting an optional remote control unit to the welding machine.
TIG Welding
Information on TIG welding setup, including the use of a Hi-Freq unit and required grounding.
OPERATING INSTRUCTIONS
To Start the Welder
Steps to safely power on the welding machine and activate the pilot light.
To Set Polarity
Instructions for selecting the correct DC polarity for the welding application.
To Set Welding Current
Guidance on adjusting the welding current using the 'Current Control' dial and selector switch.
DUTY CYCLE
Explanation of the welder's duty cycle rating and its implications for operation.
MAINTENANCE
General Maintenance
Routine maintenance tasks for the welder, including fan cleaning and lubrication.
Overload Protection
Description of the welder's built-in overload protection systems and how they function.
TROUBLE SHOOTING
Starter Chatters
Troubleshooting steps for a welding machine starter that chatters or vibrates abnormally.
Machine Starter Does Not Operate
Steps to diagnose and fix issues when the welding machine's starter fails to engage.
Machine Starter Closes But Has No (or Low) Output
Procedures for troubleshooting low or no output voltage when the starter operates.
Machine Has Maximum Output But No Control
Diagnosing issues where the welder provides maximum output but lacks current control.
Machine Does Not Have Maximum Output
Steps to check and resolve problems causing the welder to have insufficient maximum output.
Machine Trips Off While Under Load (Thermostat Tripped)
Troubleshooting machine trips due to thermostat activation under load.
Machine Comes On But Reduces to Low Output Under Load
Diagnosing output reduction under load for the welding machine.
Machine Trips Off When Under No Load or Makes Excessive Noise
Addressing unexpected trips or noise when the welder is not under load.
Variable or Sluggish Welding Arc
Troubleshooting tips for an inconsistent or sluggish welding arc.
Welder Won't Shut Off
Resolving issues where the welding machine fails to turn off.
Polarity Switch Will Not Turn
Diagnosing and fixing a stiff or non-functional polarity switch.
Welding Harsh - Too Much Spatter
Solutions for harsh welding with excessive spatter and difficult arc starting.
Current Control Not Functioning (Machine)
Troubleshooting a non-functional machine current control.
Optional Remote Current Control Not Functioning
Diagnosing and repairing issues with the optional remote current control.
Welding Okay, Then Momentary Loss of Control
Addressing momentary losses of control during normal welding operations.
Welder Has Minimum Output With No Control
Troubleshooting minimum output and lack of control on the welder.
Welder Has Excessively Higher Output Than Dial Indicates
Diagnosing output exceeding the dial setting on the welder.
LIMITED WARRANTY
STATEMENT OF WARRANTY
Details Lincoln Electric's warranty coverage for new equipment against defects in workmanship and material.
WARRANTY PERIOD
Outlines the duration of warranty coverage for different types of welding equipment.
TO OBTAIN WARRANTY COVERAGE
Instructions on how to notify Lincoln Electric or its distributors to claim warranty service.
WARRANTY REPAIR
Explains the process and conditions under which warranty repairs or replacements are performed.
WARRANTY COSTS
Information regarding the customer's responsibility for shipping costs related to warranty service.
WARRANTY LIMITATIONS
Specifies limitations on warranty claims, including unauthorized repairs and consequential damages.
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