Page 2 - SAFETY; IDEALARC R3R; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY i i IDEALARC R3R FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ___________________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY ii ii IDEALARC R3R ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield...
Page 4 - iii
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iii iii IDEALARC R3R FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC SAFETY iv iv IDEALARC R3R PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les préca...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page; RETURN TO MAIN INDEX
MASTER TABLE OF CONTENTS FOR ALL SECTIONS v v IDEALARC R3R Page Safety .................................................................................................................................................i-iv Installation .....................................................................
Page 7 - TABLE OF CONTENTS; Installation; Lifting
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section A-1 Section A-1 IDEALARC R3R TABLE OF CONTENTS - INSTALLATION SECTION - Installation ..........................................................................................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - IDEALARC R3R-300
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-2 A-2 IDEALARC R3R TECHNICAL SPECIFICATIONS - IDEALARC R3R-300 INPUT - THREE PHASE ONLY Standard Voltage ...
Page 9 - TECHNICAL SPECIFICATIONS - IDEALARC R3R-400
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-3 A-3 IDEALARC R3R TECHNICAL SPECIFICATIONS - IDEALARC R3R-400 INPUT - THREE PHASE ONLY Standard Voltage ...
Page 10 - TECHNICAL SPECIFICATIONS - IDEALARC R3R-500
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-4 A-4 IDEALARC R3R TECHNICAL SPECIFICATIONS - IDEALARC R3R-500 INPUT - THREE PHASE ONLY Standard Voltage ...
Page 11 - SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; LIFTING
Read this entire installation section before youstart installation. SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with yourskin or wet clothing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. Only qualified person...
Page 12 - INPUT CONNECTIONS; Technical Specifications; GROUND CONNECTION
INPUT CONNECTIONS ELECTRIC SHOCK can kill. • Have a qualified electrician install and service this equip-ment. • Turn the input power off at the fuse box before working on thisequipment. • Do not touch electrically hot parts. • Insulate yourself from the work and ground. • Always wear dry insulating...
Page 13 - Figure; INPUT WIRE AND FUSE SIZE
Have a qualified electrician connect the input powerleads to the L1, L2, and L3 terminals of the input con-tactor. Follow all national and local electrical codes.Use a three-phase line. Refer to the connection dia-gram located on the inside of the access panel coverfor proper input voltage connectio...
Page 14 - RECONNECT PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC INSTALLATION A-8 A-8 IDEALARC R3R FIGURE A.3 - INPUT CONNECTION DIAGRAM FOR 208, 208/230 and 230/460 VOLTS AC, 50/60 HZ ...
Page 15 - TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE
The output (welding) cables are connected to the out-put terminals marked “+” and “-”. See Table A.1 forrecommended cable sizes for the combined lengths ofelectrode and work cables. The output terminals arelocated at the lower right and lower left corners of thefront panel. Strain relief for the cab...
Page 16 - NOTES
NOTES A-10 A-10 IDEALARC R3R Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC
Page 17 - Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section B-1 Section B-1 IDEALARC R3R TABLE OF CONTENTS - OPERATION SECTION - Operation ................................................................................................................................
Page 18 - OPERATING INSTRUCTIONS; OPERATION
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC B-2 B-2 IDEALARC R3R OPERATING INSTRUCTIONS Read and understand this entire section of operatinginstructions before oper...
Page 19 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; Amps
GENERAL DESCRIPTION The Idealarc R3R is an SCR controlled constant cur-rent DC output power source for welding and cutting.The R3R-300 uses a single range potentiometer con-trol. The R3R-400 and R3R-500 have separate lowand high range controls. The welder’s unique combi-nation of 3 phase transformer...
Page 20 - CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS; Energizes; OUTPUT CONTROL POTENTIOMETER:
CONTROLS AND SETTINGS All operator controls and settings are located on thecase front assembly. See Figure B.1 for their loca-tions. FIGURE B.1 – CASE FRONT CONTROLS 1. POWER SOURCE PILOT LIGHT : This light indi- cates that input power is applied to the R3R andthat the on/off switch is in the ON pos...
Page 21 - Displays output; THERMAL PROTECTION INDICATOR LIGHT:
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC OPERATION B-5 B-5 IDEALARC R3R 8. POLARITY SWITCH (optional): Permits chang- ing the electrode polarity of the output te...
Page 22 - WELDING OPERATION; OPERATING STEPS; LOCAL CONTROL; Accessories
WELDING OPERATION OPERATING STEPS LOCAL CONTROL The following procedures are for using the IdealarcR3R in the local (“R3R”) control mode of operation.For remote control of the machine, see the REMOTECONTROL section. Before operating the machine, make sure you have allmaterials needed to complete the...
Page 24 - FACTORY INSTALLED OPTIONS; POLARITY SWITCH; FIELD INSTALLED OPTIONS; AmptrolTM; ACCESSORIES
OPTIONS/ACCESSORIES FACTORY INSTALLED OPTIONS POLARITY SWITCH Permits changing polarity at the machine output ter-minals. METERS Ammeter and Voltmeter. POCKET AMPTROL Provides a wireless remote current control for R3Rwelders. See the Operation section for details. FIELD INSTALLED OPTIONS The followi...
Page 25 - Maintenance
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section D-1 Section D-1 IDEALARC R3R TABLE OF CONTENTS - MAINTENANCE SECTION - Maintenance ............................................................................................................................
Page 26 - MAINTENANCE
SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Only qualified personnel should perform this mainte-nance. • Turn the input power OFF at the disconnect switch or fusebox before working on thisequipment. • Do not touch electrically hot parts. ROUTINE AND PERIODIC MAINTENANCE Perform the following daily...
Page 29 - Theory of Operation
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section E-1 Section E-1 IDEALARC R3R TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Theory of Operation ............................................................................................................
Page 30 - THEORY OF OPERATION
GENERAL DESCRIPTION The Idealarc R3R welder is a three-phase transformerrectifier type constant current power source designedfor DC manual welding and air carbon arc cutting. Itspower system is SCR controlled with solid state elec-tronic circuitry. Minimum to maximum output isobtained with a single ...
Page 34 - SCR OPERATION
SCR OPERATION A silicon controlled rectifier (SCR) is a three terminaldevice used to control rather large currents to a load.An SCR acts very much like a switch. When a gatesignal is applied to the SCR, it is turned ON and thereis current flow from anode to cathode. In the ONstate, the SCR acts like...
Page 35 - Troubleshooting & Repair Section; Test Procedures
Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Section F-1 Section F-1 IDEALARC R3R TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - Troubleshooting & Repair Section ..................................................................................
Page 36 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; The; Step 3. PERFORM COMPONENT TESTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personn...
Page 37 - PC BOARD TROUBLESHOOTING PROCEDURES
ELECTRIC SHOCK can kill. Have an electrician install and servicethis equipment. Turn the machine OFFbefore working on equipment. Do nottouch electrically hot parts. Sometimes machine failures appear to be due to PCboard failures. These problems can sometimes betraced to poor electrical connections. ...
Page 38 - Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Input Contactor
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-4 F-4 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 40 - Main Transformer
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-6 F-6 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 41 - Make certain the Dial Control
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-7 F-7 IDEALARC R3R TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginn...
Page 42 - Rectifier Bridge Test.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-8 F-8 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 43 - WELDING PROBLEMS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-9 F-9 IDEALARC R3R Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginn...
Page 44 - INPUT CONTACTOR TEST; DESCRIPTION; This procedure takes approximately 20 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-10 F-10 IDEALARC R3R INPUT CONTACTOR TEST (FOR MODELS EQUIPPED WITH AC COIL ON INPUT CONT...
Page 45 - TEST PROCEDURE; Electric Shock can kill.; FIGURE F.1 – AC COIL INPUT CONTACTOR CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-11 F-11 IDEALARC R3R INPUT CONTACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the ma...
Page 46 - TEST FOR CONTACT CONTINUITY; Disconnect the main input supply power to; FIGURE F.2 – AC COIL INPUT CONTACTOR TEST POINT LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-12 F-12 IDEALARC R3R TEST FOR CONTACT CONTINUITY 1. Disconnect the main input supply powe...
Page 48 - FIGURE F.3 – DC COIL INPUT CONTACTOR CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-14 F-14 IDEALARC R3R INPUT CONTACTOR TEST (continued) TEST PROCEDURE 1. Disconnect the ma...
Page 49 - FIGURE F.4 – DC COIL INPUT CONTACTOR TEST POINT LOCATIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-15 F-15 IDEALARC R3R TEST FOR CONTACT CONTINUITY 1. Disconnect the main input supply powe...
Page 50 - This procedure takes approximately 17 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-16 F-16 IDEALARC R3R WARNING CONTROL TRANSFORMER (T2) VOLTAGE TEST Service and repair sho...
Page 51 - Unused leads should be taped.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-17 F-17 IDEALARC R3R CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) FIGURE F.5 – CONTR...
Page 52 - If the main AC input supply voltage; FIGURE F.6 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-18 F-18 IDEALARC R3R CONTROL TRANSFORMER (T2) VOLTAGE TEST (continued) 6. Test for 115VAC...
Page 53 - This procedure takes approximately 25 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-19 F-19 IDEALARC R3R WARNING MAIN TRANSFORMER (T1) VOLTAGE TEST Service and repair should...
Page 55 - Test with an AC voltmeter for proper main; FIGURE F.8 – MAIN SECONDARY LEAD TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-21 F-21 IDEALARC R3R 8. Read the meter. a. If proper voltage is present for all threephas...
Page 56 - PHASE ANGLE WINDING TEST; Test with an AC voltmeter for approximate-; NOTE; : If the main input supply voltage
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-22 F-22 IDEALARC R3R PHASE ANGLE WINDING TEST 12. Test with an AC voltmeter for approxima...
Page 57 - Expected VAC
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-23 F-23 IDEALARC R3R TABLE F.1 – PHASE ANGLE WINDING VOLTAGES From Lead # To Lead # Expec...
Page 59 - STATIC SCR/DIODE RECTIFIER BRIDGE TEST; FIGURE F.11 – CONTROL BOARD; Be sure to disconnect the #204
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-25 F-25 IDEALARC R3R STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) FIGURE F.11 – CON...
Page 60 - RESISTOR R3; Plug P5
TROUBLESHOOTING & REPAIR F-26 F-26 IDEALARC R3R Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC FIGURE F.14 – RESISTOR R3 LOCATION FIGURE F.13 – SNUBBER BOARD M1537...
Page 61 - Active; FIGURE F.15 – HEAT SINK AND SCR TEST POINTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-27 F-27 IDEALARC R3R STATIC SCR/DIODE RECTIFIER BRIDGE TEST (continued) 7. Remove the red...
Page 62 - This procedure takes approximately 30 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-28 F-28 IDEALARC R3R WARNING ACTIVE SCR TEST Service and repair should be performed by on...
Page 63 - ACTIVE SCR TEST
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-29 F-29 IDEALARC R3R ACTIVE SCR TEST (continued) TEST PROCEDURE 1. Disconnect the main in...
Page 64 - FIGURE F.20 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-30 F-30 IDEALARC R3R ACTIVE SCR TEST (continued) 7. Remove the red insulating paint from ...
Page 65 - This procedure takes approximately 18 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-31 F-31 IDEALARC R3R WARNING POCKET AMPTROL CIRCUIT TEST Service and repair should be per...
Page 66 - POCKET AMPTROL CIRCUIT TEST; TRANSFORMER
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-32 F-32 IDEALARC R3R POCKET AMPTROL CIRCUIT TEST (continued) TEST PROCEDURE 1. Remove inp...
Page 68 - FIGURE F.23 – SENSING RESISTOR R4
TROUBLESHOOTING & REPAIR F-34 F-34 IDEALARC R3R Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC POCKET AMPTROL CIRCUIT TEST (continued) FIGURE F.23 – SENSING RESIST...
Page 69 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; MAXIMUM OUTPUT SETTING – NO LOAD; volts
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-35 F-35 IDEALARC R3R This is the typical DC open circuitvoltage waveform generated from a...
Page 70 - TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-36 F-36 IDEALARC R3R This is the typical DC voltage wave-form generated from a properly o...
Page 71 - TYPICAL SCR GATE VOLTAGE WAVEFORM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-37 F-37 IDEALARC R3R This is the typical SCR gate pulsevoltage waveform. The machine wasi...
Page 72 - ABNORMAL OUTPUT VOLTAGE WAVEFORM; ONE OUTPUT SCR NOT FUNCTIONING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-38 F-38 IDEALARC R3R This is NOT the typical DC outputvoltage waveform. One output SCRis ...
Page 73 - The contactor cleaning procedure takes approximately
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-39 F-39 IDEALARC R3R WARNING INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT Service and repai...
Page 74 - CLEANING PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-40 F-40 IDEALARC R3R INPUT CONTACTOR (CR1) CLEANING/REPLACEMENT (continued) FIGURE F.25 –...
Page 76 - FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT; FIGURE F.26 – FAN MOTOR MOUNTING DETAILS; PROCEDURE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-42 F-42 IDEALARC R3R FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT (continued) FIGURE F.26 ...
Page 77 - This procedure takes approximately 35 minutes to perform.
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-43 F-43 IDEALARC R3R WARNING SCR/DIODE RECTIFIER ASSEMBLY REMOVAL AND REPLACEMENT Service...
Page 78 - SCR/DIODE RECTIFICER ASSEMBLY; CHOKE
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-44 F-44 IDEALARC R3R SCR/DIODE RECTIFICER ASSEMBLY REMOVAL AND REPLACEMENT (continued) FI...
Page 79 - REASSEMBLY; TROUBLESHOOTING
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 themounting brackets. 15. Reattach the three heavy aluminum secondary leads and snubber leads to ...
Page 81 - SCR REMOVAL AND REPLACEMENT; SPECIAL INSTRUCTIONS; bly Removal
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-47 F-47 IDEALARC R3R FIGURE F.28 – SCR DETAILS SCR REMOVAL AND REPLACEMENT (continued) SP...
Page 82 - Go to the procedure below that matches your
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-48 F-48 IDEALARC R3R FIGURE F.29 – 1/2” WIDE LEAF SPRING FIGURE F.30 – CLAMP ASSEMBLY HEX...
Page 84 - FIGURE F.31 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-50 F-50 IDEALARC R3R SCR REMOVAL AND REPLACEMENT (continued) PROCEDURE FOR THE5/8 INCH WI...
Page 85 - AFTER REPLACING THE SCRs; Removal and Replacement
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-51 F-51 IDEALARC R3R CLAMPING PROCEDURE FOR 1/4-28 CAP SCREWS NOTE: This procedure can on...
Page 86 - This procedure takes approximately 20 minutes
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-52 F-52 IDEALARC R3R WARNING MOUNTING OF STUD TYPE DIODES TO ALUMINUM HEAT SINKS Service ...
Page 87 - Install the case top and sides.; DIODE STUD; MOUNTING OF STUD TYPE DIODES TO ALUMINUM
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-53 F-53 IDEALARC R3R PROCEDURE 1. Remove the main input supply power to themachine. 2. Wi...
Page 88 - This procedure takes approximately 3 to 5 hours
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-54 F-54 IDEALARC R3R WARNING MAIN TRANSFORMER REMOVAL AND REPLACEMENT Service and repair ...
Page 89 - REMOVAL OF LIFT BAIL; Remove the lift bail by lifting straight up and; MAIN TRANSFORMER REMOVAL & REPLACEMENT; FIGURE F.33 – LIFT BAIL REMOVAL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-55 F-55 IDEALARC R3R REMOVAL OF LIFT BAIL 1. Remove the main input supply power to themac...
Page 91 - Apply a coating of Lincoln Electric E2547
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-57 F-57 IDEALARC R3R FIGURE F.35 – EPOXY MIX APPLICATION AREAS MAIN TRANSFORMER REMOVAL &...
Page 93 - If necessary, trim off excess secondary lead; FIGURE F.38 – SECONDARY LEAD TRIM AND WELD DETAIL
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-59 F-59 IDEALARC R3R MAIN TRANSFORMER REMOVAL & REPLACEMENT (continued) 10. If necess...
Page 94 - REASSEMBLE THE LIFT BAIL
REASSEMBLING THE MAINTRANSFORMER INTO THE MACHINE NOTE: The following procedure assumes you havecompletely reassembled the transformer coilsas described in the procedure above. Thelower iron has remained in place in themachine. See Figures F.26 and F.27. 1. Resolder the choke thermostat lead. 2. Att...
Page 95 - INPUT IDLE AMPS AND WATTS
Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TROUBLESHOOTING & REPAIR F-61 F-61 IDEALARC R3R RETEST AFTER REPAIR (R3R 300) Retest a machine: • If it is rejected ...
Page 99 - Electrical Diagrams
ELECTRICAL DIAGRAMS G-1 G-1 Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Section TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC Retur n to Master TOC TABLE OF CONTENTS - ELECTRICAL DIAGRAMS SECTION - Electrical Diagrams .........................
Page 101 - ELECTRICAL DIAGRAMS
G-3 ELECTRICAL DIAGRAMS R3R Wiring Diagram-R3R-300 ELECTRICAL SYMBOLS PER E1537 LEGEND D5 D6 D7 POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER R1 R2 R3 R4 15 14 13 4 5 6 7 8 9 TO SUPPLY LINES TO GROUND PER NATIONAL ELECTRICAL CODE 1 2 3 L1 L2 L3 H3 H2 H1 X2 X1 T2 RECONNECT PANEL SHOWN CONNECTED F...
Page 104 - Pocket Amptrol Schematic
G-6 ELECTRICAL DIAGRAMS R3R Pocket Amptrol Schematic 3 3 . 2 K R 3 8 X 1 1 4 1 2 1 3 Q 3 4 7 5 R10 6 8 . 1 K R44 3 3 . 2 K R 3 9 D 9 3 3 . 2 K R 5 6 1 W 1 2 V D Z 1 D 3 1 0 05 0 V C 4 6 8 . 1 K R51 1 5 J 5 0 V T P 1 3 3 . 2 K R62 1 W 1 2 V D Z 2 1 0 . 0 R 2 9 D 4 1 0 . 0 R 3 0 1 0 05 0 V C 5 4 7 5 R...
Page 105 - Snubber Board Schematic & Layout
G-7 ELECTRICAL DIAGRAMS R3R Snubber Board Schematic & Layout 1 AMP/400 VOLT (UNLESS OTHERWISE SPECIFIED) LM124 (UNLESS OTHERWISE SPECIFIED) COMMON CONNECTION = = OP AMPS = DIODES = RESISTORS MFD/VOLTS ON 3 PLACE DECIMALS IS + .OO2 = CAPACITORS ELECTRICAL SYMBOLS PER E1537 J5 6 OHMS,1/4 WATT (UNL...
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