Lincoln Electric R3R-300 - Manual

Lincoln Electric R3R-300

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Table of Contents:

  • Page 2 – SAFETY; IDEALARC R3R; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – MASTER TABLE OF CONTENTS FOR ALL SECTIONS; Page; RETURN TO MAIN INDEX
  • Page 7 – TABLE OF CONTENTS; Installation; Lifting
  • Page 8 – INSTALLATION; TECHNICAL SPECIFICATIONS - IDEALARC R3R-300
  • Page 9 – TECHNICAL SPECIFICATIONS - IDEALARC R3R-400
  • Page 10 – TECHNICAL SPECIFICATIONS - IDEALARC R3R-500
  • Page 11 – SAFETY PRECAUTIONS; SELECT SUITABLE LOCATION; LIFTING
  • Page 12 – INPUT CONNECTIONS; Technical Specifications; GROUND CONNECTION
  • Page 13 – Figure; INPUT WIRE AND FUSE SIZE
  • Page 14 – RECONNECT PROCEDURE
  • Page 15 – TABLE A.1 - CABLE SIZES FOR COMBINED LENGTHS OF COPPER ELECTRODE
  • Page 16 – NOTES
  • Page 17 – Operation
  • Page 18 – OPERATING INSTRUCTIONS; OPERATION
  • Page 19 – GENERAL DESCRIPTION; RECOMMENDED PROCESSES; Amps
  • Page 20 – CONTROLS AND SETTINGS; FIGURE B.1 – CASE FRONT CONTROLS; Energizes; OUTPUT CONTROL POTENTIOMETER:
  • Page 21 – Displays output; THERMAL PROTECTION INDICATOR LIGHT:
  • Page 22 – WELDING OPERATION; OPERATING STEPS; LOCAL CONTROL; Accessories
  • Page 24 – FACTORY INSTALLED OPTIONS; POLARITY SWITCH; FIELD INSTALLED OPTIONS; AmptrolTM; ACCESSORIES
  • Page 25 – Maintenance
  • Page 26 – MAINTENANCE
  • Page 29 – Theory of Operation
  • Page 30 – THEORY OF OPERATION
  • Page 34 – SCR OPERATION
  • Page 35 – Troubleshooting & Repair Section; Test Procedures
  • Page 36 – HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR; CAUTION; The; Step 3. PERFORM COMPONENT TESTS
  • Page 37 – PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 38 – Observe Safety Guidelines; TROUBLESHOOTING GUIDE; detailed in the beginning of this manual.; OUTPUT PROBLEMS; Input Contactor
  • Page 40 – Main Transformer
  • Page 41 – Make certain the Dial Control
  • Page 42 – Rectifier Bridge Test.
  • Page 43 – WELDING PROBLEMS
  • Page 44 – INPUT CONTACTOR TEST; DESCRIPTION; This procedure takes approximately 20 minutes to perform.
  • Page 45 – TEST PROCEDURE; Electric Shock can kill.; FIGURE F.1 – AC COIL INPUT CONTACTOR CONNECTIONS
  • Page 46 – TEST FOR CONTACT CONTINUITY; Disconnect the main input supply power to; FIGURE F.2 – AC COIL INPUT CONTACTOR TEST POINT LOCATIONS
  • Page 48 – FIGURE F.3 – DC COIL INPUT CONTACTOR CONNECTIONS
  • Page 49 – FIGURE F.4 – DC COIL INPUT CONTACTOR TEST POINT LOCATIONS
  • Page 50 – This procedure takes approximately 17 minutes to perform.
  • Page 51 – Unused leads should be taped.
  • Page 52 – If the main AC input supply voltage; FIGURE F.6 – CONTROL TRANSFORMER X1 AND X2 TEST CONNECTIONS
  • Page 53 – This procedure takes approximately 25 minutes to perform.
  • Page 55 – Test with an AC voltmeter for proper main; FIGURE F.8 – MAIN SECONDARY LEAD TEST POINTS
  • Page 56 – PHASE ANGLE WINDING TEST; Test with an AC voltmeter for approximate-; NOTE; : If the main input supply voltage
  • Page 57 – Expected VAC
  • Page 59 – STATIC SCR/DIODE RECTIFIER BRIDGE TEST; FIGURE F.11 – CONTROL BOARD; Be sure to disconnect the #204
  • Page 60 – RESISTOR R3; Plug P5
  • Page 61 – Active; FIGURE F.15 – HEAT SINK AND SCR TEST POINTS
  • Page 62 – This procedure takes approximately 30 minutes to perform.
  • Page 63 – ACTIVE SCR TEST
  • Page 64 – FIGURE F.20 – SCR TESTER CIRCUIT AND SCR CONNECTIONS
  • Page 65 – This procedure takes approximately 18 minutes to perform.
  • Page 66 – POCKET AMPTROL CIRCUIT TEST; TRANSFORMER
  • Page 68 – FIGURE F.23 – SENSING RESISTOR R4
  • Page 69 – SCOPE SETTINGS; NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM; MAXIMUM OUTPUT SETTING – NO LOAD; volts
  • Page 70 – TYPICAL OUTPUT VOLTAGE WAVEFORM – MACHINE LOADED
  • Page 71 – TYPICAL SCR GATE VOLTAGE WAVEFORM
  • Page 72 – ABNORMAL OUTPUT VOLTAGE WAVEFORM; ONE OUTPUT SCR NOT FUNCTIONING
  • Page 73 – The contactor cleaning procedure takes approximately
  • Page 74 – CLEANING PROCEDURE
  • Page 76 – FAN MOTOR AND BLADE REMOVAL AND REPLACEMENT; FIGURE F.26 – FAN MOTOR MOUNTING DETAILS; PROCEDURE
  • Page 77 – This procedure takes approximately 35 minutes to perform.
  • Page 78 – SCR/DIODE RECTIFICER ASSEMBLY; CHOKE
  • Page 79 – REASSEMBLY; TROUBLESHOOTING
  • Page 81 – SCR REMOVAL AND REPLACEMENT; SPECIAL INSTRUCTIONS; bly Removal
  • Page 82 – Go to the procedure below that matches your
  • Page 84 – FIGURE F.31 – HOUSING AND PRESSURE PAD FOR 5/8” WIDE LEAF SPRING
  • Page 85 – AFTER REPLACING THE SCRs; Removal and Replacement
  • Page 86 – This procedure takes approximately 20 minutes
  • Page 87 – Install the case top and sides.; DIODE STUD; MOUNTING OF STUD TYPE DIODES TO ALUMINUM
  • Page 88 – This procedure takes approximately 3 to 5 hours
  • 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
  • Page 91 – Apply a coating of Lincoln Electric E2547
  • Page 93 – If necessary, trim off excess secondary lead; FIGURE F.38 – SECONDARY LEAD TRIM AND WELD DETAIL
  • Page 94 – REASSEMBLE THE LIFT BAIL
  • Page 95 – INPUT IDLE AMPS AND WATTS
  • Page 99 – Electrical Diagrams
  • Page 101 – ELECTRICAL DIAGRAMS
  • Page 104 – Pocket Amptrol Schematic
  • Page 105 – Snubber Board Schematic & Layout
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SVM139-A

June 1998

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

For use with machine code numbers

9534, 9537, 9874

and

9884

IDEALARC

®

R3R-300, -400 and -500

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RETURN TO MAIN INDEX

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Summary

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...

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